Turn a Dusty Old Beam into a Stunning DIY Light Fixture
Transform an old hand-hewn barn beam into a beautiful rustic light fixture. This DIY project adds character and warmth to any space while creating a unique conversation piece for your home.
The Build: Step-by-Step
Step 1: Find Your Beam
You need a beam thick enough to house a light bulb - I recommend at least 6" thick. Finding a beam of this length should be relatively easy, as most people hunting for hand-hewn barn beams are looking to build something much longer. Our barn beam light fixture measures 4"x4"x 3.5'. Cut your beam to the desired length using your miter saw or circular saw.
Step 2: Lay Out Your Design
I love this lightbulb. It's long, has smoked grey glass and edison style filament (even though it's LED). The first thing to do is determine where the bulb will go. Take a pencil and trace the outline of the lightbulb and the lightbulb socket on to the wood.
Step 3: Hollow Out the Core
This is an arduous process but not a complicated one. I tried various tools, but the method that worked best was using a hand drill with forstner bits. Drill holes as deep as you can within the traced line. Make the socket side pretty tight and give some extra breathing room around the bulb. Then use your hammer and chisel to clean up the wood. Repeat until the bulb and socket fit snugly.
Step 4: Test Fit and Light Distribution
Critical step that you should not overlook: test the fit AND the light distribution. Set the bulb in and plug in the light. The focus is on light distribution. During this test, I noticed some cool cracks that were too narrow to allow light to escape. I used a chisel to widen these cracks. Do not rush this step. The goal isn't just to make a light—it's to make a light that looks exactly how you want it.
Step 5: Mount and Finish
My DIY bar has pipe for a footrest and shelves. I wanted to tie everything together with this light fixture using matching pipe fittings. The most important part is to screw fittings into ceiling joists - never hang a fixture like this with drywall anchors. Apply polyurethane to the beam, focusing on all cracks and crevices, for that perfect rustic look.
