Pumpkin From a Propane Tank

Pumpkin decoration made from an empty camping propane tank.

Empty 1lb. propane tank
Valve core removal tool (see step 2 to make one)
Rotary tool
Metal cutting disc for rotary tool
Sanding attachment for rotary tool or paint stripper
Spray paint (orange and green)
Optional:
Small hinge
JB Weld or similar epoxy
Magnets
Lights for inside the pumpkin

I had a left over 1lb tank from camping. Same ones you use for a small propane camp stove.

You can buy a premade tool for anywhere from $6-$13 Or you can make one yourself from an old flathead screwdriver. If there isn’t one laying around harbor freight tool sells them for $1.99 and you can use the same rotary tool to make a notch in the middle for the valve core. Or use a hacksaw.

Make sure the propane tank is empty. If you aren’t sure just connect the tank to a bbq or other device that uses propane. Light the bbq, lantern, heater ect, until the propane runs out.
In a well ventilated area use your newly acquired valve core removal tool (VCT) to unscrew the valve on the propane tank.
Careful as there will probably still be some gas inside so don’t point it at yourself or anyone else.
Insert the VCT into the valve and gently unscrew enough to start venting.
Once it is empty continue to unscrew the valve core until it comes out.

Using a sanding disc or paint stripper remove the old paint from the tank.
This can be time consuming depending on the method but is worth it to have a good base to repaint onto.
Clean the bare metal with acetone to remove any residue.

Draw whatever jack O lantern face you like. I went with a classic triangle toothy grin but your design is your choice. Remember the more intercut the design the harder it will be to cut out.
Secure the propane tank for cutting.
Using a rotary tool and a metal cutoff disc cut out the design.

If you want to be able to access the inside of the pumpkin to add lights.
Cut off the top of the propane tank and add a hinge.
I used JB Weld fast set to secure the hinge to the inside of the propane tank and lid. Other epoxies or glue might work I just know Jb works. Hot glue may even work as a quick option.
Do one side at a time so you don’t have to figure out how to clamp both the lid and the body of the pumpkin.
It came out okay but I would use a different hinge if I did it again I was just limited by selection.
Add magnets inside the lid and wall of the body to keep the lid closed.

I used spray paint. Lowe’s had “Pumpkin Orange” in stock and it seemed perfect
Go slow keep moving and avoid heavy application. I want to paint it on thick and be done but it’s best to do 2,3 or 4 coats evenly. Fallow the instructions for dry times in between coats.
Once the orange is on and dry mask it off for the green on the stem. I used “emerald green” but almost any shade would work after all pumpkins grown in all shapes sizes and colors.

Add whatever lights you like or just enjoy without.