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8 Halloween Welding Projects to Try Today (With Pictures and Videos)

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halloween graveyard decoration

Fall is when people take pictures of their boots in the leaves while drinking pumpkin spice lattes, but maybe you’re not that kind of person. Maybe, you’d rather celebrate the fall season by creating some incredible Halloween decorations. Check out a few of the best Halloween welding projects we’ve found for you.

The 8 Halloween Welding Projects Are:

1. Spooky Pot Stand

Materials: Round Bar
Tools: Welder, Grinder, Saw
Difficulty: Moderate

This flowerpot stand is made entirely of round bar. The top and bottom are octagonal. Make sure to cut out equal lengths and stagger your tacks and welds to prevent warping. The top octagon will be filled in with layers of round bar so that it looks like a spider’s web. The legs are made of four equal lengths of round bar. Paint it orange or green when you’re done for a Halloween festive flair.


2. Spider Light from Rebar

Materials: Rebar, Old Steel Air Tank, Lightbulb, Lightbulb Socket
Tools: Bandsaw, Welder, Grinder
Difficulty: Moderate

Check out this eerie-looking spider light made from rebar and an old steel air tank that has been cut. If you draw out a template with precise measurements, you can simply transfer it to the pieces you cut. The spider’s body is made from the cut piece of the air tank. The outside of the body has a cord that powers the lightbulb, and the inside of the air tank houses the lightbulb socket.


3. Pumpkins Made from Horseshoes

Materials: Horseshoes, Spray Paint
Tools: Welder, Grinder, Saw
Difficulty: Easy

All you have to do to make this awesome pumpkin is tack the heels of two horseshoes together. Then, you can do the same for the remaining three pairs of horseshoes but use the first set as a base, meaning that you will end up tacking all of the horseshoes together. Cut another horseshoe for the stem, either using a cut-off wheel (and then softening the edges with a grinder) or a bandsaw. This will be tacked on the top of the pumpkin. Paint it orange and green after welding.


4. Black Widow Spider

Materials: Thick Plate (1” or more), Round Bar
Tools: Welder, Grinder, Saw
Difficulty: Moderate

What makes this one so spooky has got to be the face. The design is totally up to you, but a good strategy is to create what is shown in the video. Draw your plan on your piece of plate with a paint pen or something else that is highly visible, and weld beads into the pattern. Cut your pieces of round bar and grind them all down to a point. Don’t use just one piece of round bar per leg; use at least a couple of pieces so that the legs look slightly crooked. When you weld them together, ensure that the parts have a slight overlap so that the points are revealed.


5. Scrap Metal Skull

Materials: Thin Gauge Steel
Tools: Welder, Grinder, Hammer
Difficulty: Difficult

What makes a project like this so tricky is that aside from not having a suitable jig or template (unless you happen to have a spare skull lying around), it’s hard to control the exact dimensions you want for your piece as you’re welding it. You could easily tack up pieces of cut sheet metal together, but keeping them in the spot you fit them will be challenging once you start distributing heat through welding.


6. Forged Steel Ghost

Materials: Thin Sheet Metal
Tools: Welder, Hand Plate Shear, Grinder, Hammer, Anvil
Difficulty: Difficult

Cut out a perfect sheet metal circle using a saw or a hand plate shear, and then cut out one-quarter of the circle. Bend your remaining piece of sheet metal around the back of your anvil so that both ends of the ¾ circle meet. It should have a conical shape, and you can tack up the ends together. Then it’s just a matter of being delicate yet firm in your hammering around the edges to achieve the looks of the sheet folds. Cut some holes for the eyes and mouth. Simply haunting!


7. Pumpkin Spider

Materials: Round Bar, Rebar
Tools: Rod bender, Grinder, Welder
Difficulty: Moderate

Using two lengths of round bar (based on the circumference of two different pumpkins), bend them into circles and set them side by side. Measure the lengths between the sides of the circles and cut out two pieces of round bar for additional support. Weld them to your circles, cut eight equal lengths of rebar, and grind down the ends to look like leg talons. Make a couple of notches down the length of your rebar on each piece so that it will bend easier. This will form the knee joints. Cut an angle on the opposite end of the talons so that the spider’s body sits flush with the legs. Weld it up, and you’re done!


8. Jack-O-Lantern

Materials: Papercraft Jack-O-Lantern Kit, Sheet metal
Tools: Bandsaw, Welder, Grinder
Difficulty: Moderate

One great thing about buying a kit for a project is that you don’t have to take any of your own measurements. Watch how the designer takes each piece of paper and uses it to cut out his sheet metal. You will have to notch the metal at certain points, so it bends easier. As with all thin metals, you must try to stagger your tacks and welds to prevent heat distortion, especially with a project with no internal structural support. When you’re done welding, you can either go for a cleaner look by grinding down some of your welds or keep them intact.


Final Thoughts

Fall is a festive season in no small part due to Halloween. Welding is a great way to make front porch decorations that will spook your trick-or-treaters (especially if your welding isn’t that pretty!). Since many of these designs are artistic, you also have some license to alter the structure as you see fit. Always use proper PPE (gloves, eyewear, hood, ear protection) when working on any welding project.

Other projects that you can try:


Featured Image Credit: Dr. Ina Melny, Unsplash

Cameron Dekker
 

Cameron grew up in Allentown, Pennsylvania, a once-proud steel town on the Lehigh River, where he got a taste of TIG welding in his high school shop class. He holds certificates for Certified WeldingEducator (CWE) and Certified Resistance Welding Technician (CRWT) from the American Welding Institute. His interests include scuba diving, sculpture, and kayaking.