Halloween Lanterns

This Instructable is for making the Halloween Lanterns that are available at craft shows during the early fall of the year. Although this is written for making the Lanterns using a Scroll Saw or a Jig Saw the reader could make the same thing using a CNC Router. It will also discuss various ways for finishing the Lanterns.

Tools:

1. Circular Saw, Table Saw and/or Miter Saw
2. Jig Saw or Scroll Saw
3. CNC Router (optional)
4. Computer (optional)
5. Drill
6. 1 ½” Forstner Bit
7. Bead Nailer or Hammer
8. Sander
9. Tape Measure
10. Pencil
11. Torch (optional)

Materials:

1. ½” x 2’ x 2’ plywood
2. 1’ Braid Nails
3. Wood Glue
4. Orange Stain or Paint
5. Green Stain or Paint
6. Clear Sray Paint in a Matte or Satin Finish
7. Tea Light Candle
8. Small string of Fairy Lights (optional)

1.  Using a Table Saw or Circular Saw, rip the plywood into 4 strips as follows;
2. (1 each) - 7” wide strip
3. (1 each) - 4” wide strip
4. (1 each) - 5 ¾” wide strip
5. ( 1 each) - 3 ¾” wide strip
6. Using a Table Saw, Circular Saw or Miter Saw cut the strips as follows;
7. Cut the 7” wide strip into two 9” long boards (part “A”) and set the remainder aside
8. Cut the 4” wide strip into two 9” long boards (part “B”) and set the remainder aside.
9. Cut the 5 ¾” wide strip into two 8” long boards (part “C”) and set the remainder aside. (Part “C”)
10. Cut the 3 ¾” wide strip into two 5 ¾”” long boards(part “D”) and set the remainder aside.
11. Using a Jig Saw or Scroll Saw cut your pumpkin design onto one of the pieces of part “A”.
12. Using a Jig Saw or Scroll Saw (or CNC Machine) cut the pumpkin stem out of a piece of scrap you saved.
13. In the center of one of the part “D” boards drill a 1 ½” hole halfway thru the board. Note this will create a pocket to keep the Tea Light Candle from sliding around and is not necessary if you use Fairy Lights.

1. Glue part “D” in the center of part “C” for both pieces. Set them aside to allow the glue to dry. Part “D” will act as an alignment guide for assembling the lantern. These pieces will be your Base and Top of the Lantern.

1. Put some glue on the side edge of part “B” and attach Side “A” to Side “B”. Tack the sides in place with a Brad Nailer.
2. Repeat step 1 on the other edges and assemble the whole box.

1. Apply glue to the bottom of the body,
2. Place base on the body and tack in place using a Brad Nailer

1. Apply glue to the bottom of the stem and place it in the center of the outside top. If possible, tack it in place with the Brad Nailer from the underside.Note that you will not be attaching the top to the lantern. This will allow you to open it to turn the Candle on and off.

Using 120 grit sandpaper and a Sander, sand the outside of the lantern and lid to remove any sharp edges

1. Charing wood can yield a variety of patterns depending on your technique and the grain of your wood:
2. For a light charring: Move the torch quickly over the wood for a subtle, smoky look. This method highlights the grain without deeply burning the wood.
3. For deep burns: Hold the torch closer and longer to the wood for a rich, dark finish.

1. Using an Orange Stain, stain the lantern both the inside and outside.
2. Using a Green Stain, Stain the stem.
3. If you do not have colored stains available you can make some by mixing acrylic paint with water. Start by using 2 parts paint to 1 part water.Add additional water until you receive the desired results.
4. Allow Stain to dry for 24 hrs.
5. When dry, spray a clear matte finish on the outside. 

1. Turn Tea Light Candle on and place it in the pocket inside,
2. Place the lid on the Lantern. (You could use a small string of Fairy Lights instead).
3. Enjoy!