How To Build A Lantern

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How do I build a lantern like this?

Step 1 - Draw Your Plan

Sketch a picture of your lantern. Look for existing lanterns that you like or create something new!

Use a pencil and a straightedge to draw your lantern. Any type of paper will work. Your drawing does not have to be to scale but it should be large enough so that you can clearly see any small details.

Remember, the more time you spend planning your lantern will greatly reduce problems later during the fabrication steps!

Step 2 - Select Your Materials

Copper and brass are the easiest metals to work with in lantern fabrication. You can purchase either at your local metal supplier (look in your Yellow Pages). Or you can purchase brass strip and brass or copper 4" x 12" sheets that are made by K&S Engineering of Chicago, IL, at most hobby stores.

The best thickness is 0.032"

Step 3 - Prepare Your Tools

You will need the following tools:

Tin-snips
File (fine)
50-50 Solder
Propane Torch (or very large electric soldering iron)
Flux
Clamps
Marking Pen
Vise or Large Pliers (for bending metal)

The best way to bend metal is by using a sheetmetal "brake" or folder. You can purchase bench-size brakes or floor-size ones at specialized hardware or industrial-supply stores (one resource: Harbor Freight mail order).

Step 4 - Mark, Cut & Bend Metal

Once you have designed your lantern, now you must transfer your design to the metal. Use tracing paper (carbon paper) to place the outlines on the brass or copper sheetmetal.

Use hand shears or a cutoff shear to trim away the excess metal. For curved sections use a jigsaw (with a metal-cutting blade) or a handsaw. Use a file to complete the cutout.

Bend the metal using a bendingbrake or a vise and plyers.Take your time and do a precise job.

24-inch sheetmetal brake

Bench brake for bending metal

36-inch floor model brake

Cutoff shear for cutting sheetmetal

Step 5 - Assemble & Solder

Once you have cut out all the metal pieces, now you must assemble them. Use clamps to hold the pieces together. Remember to apply the soldering flux paste before clamping the metal sections together.

After clamping, apply heat and solder to each joint. Remember to thoroughly remove any excess flux paste afterwards.Check each soldered joint for soundness. Re-solder as necessary.

Wash the lantern afterwards with soap and water to remove an excess flux paste. Polish the metal using fine steel wool. Use various chemicals to treat the copper or brass to create a patina.