Funky Metal Lamp Shade

I found this cool orange lamp at Goodwill for $3, and figured it needed an equally funky shade. I had the idea to use galvanized sheet metal for the shade and cut holes it in to let the light out, with fabric underneath.

The first thing I did was use some paper to make a cylinder, and figure out how large I wanted the shade to be. I then made a wooden frame that I would attach the metal to.

I used the paper shade to mark and cut my sheet metal. I left enough material so that I could fold over the edges and have an overlapping seam when I rolled it into a cylinder. I used a sheet metal folding tool like this to fold the edges most of the way, then a rubber mallet to give them a nice crease.

I used my drill press and a whole saw to cut all the holes, make sure to use plenty of 3-IN-One oil to lubricate and cool my cuts.

I used a Dremel tool and lots of sanding drums to grind down the burs and jagged edges inside the holes.

The fabric I used came from a blouse I also got at Goodwill. I first used spray adhesive to hold it to the metal, but that wasn't enough. I ended up drilling holes in between the polka-dots and using pop rivets to attach small backing plates. This held the fabric securely.

I used screws to hold the metal to the wooden frame, and pop rivets to hold the seam together.

I found a switch that was rated for 125v 20a and put it in the base.

And there we go. I'm using a LED bulb to make sure nothing gets too hot.

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This project was finished on March 11, 2018.