Last Updated on March 24, 2025 by teamobn
Log burners are the perfect way to enjoy a cozy night, and they also make a great addition to any adventure-themed decor. They give any room a warm, inviting feeling, and they’re also a great way to add a touch of rustic charm.
Whether you’re looking to add a bit of ambience to your home or you’re planning your next big camping trip, log burners are a great way to go. They’re easy to use and they add a touch of class to any setting.
The “Star Wars” movies have endured for decades. In fact, the franchise has become one of cinema’s most iconic series. And no character in the franchise is as iconic as Darth Vader! Whether you’re a die-hard fan of the movies or someone who’s just casually interested, it’s impossible to deny the impact that Vader has had.
Star Wars fan or not, we believe this is one of the most impressive DIY log burners out there. This remarkable project is fit for any Star Wars fan – or anyone who appreciates an impressive feat of DIY. It’s clear a lot of time, effort and imagination went into this project, and we think it’s simply amazing. Do you agree?
Using an empty gas tank and some scrap iron metal, this DIYer skillfully made his personalised log burner. If you are into metalworking projects, why not give this upcycled gas tank a try with your favourite character?
Click on any image to start the lightbox display. Use your Esc key to close the lightbox. 
Contents [show]
Building a Darth Vader Wood Burner
You’ll need these materials:
- Gas Bottle/Tank
- Iron Scrap
- Machine Screws
- Spray Paint
- Masking Tape
- Clippers (to hold parts in place)
And these tools:
- Marker
- Drill
- Angle Grinder with Cutting Discs
- Welding Machine
Steps to build a Darth Vader log burner from a gas bottle
Find an empty gas tank in the middle of nowhere. Carefully remove the tap and start filling it up with water. As the water starts to displace the leftover gas, you can start to scribble on your design. Make sure to go big and be creative – this is your chance to make a real statement!
For this project, you’ll need to gather up all your scrap bits and pieces to use for the detailing. Once you have everything you need, it’s time to get creative and start bringing your Darth Vader log burner to life.
This is a fun project that’s sure to impress your friends and family. So get started today and let your inner Sith Lord shine through!
I like to use masking tape to hold my bits in place. I marked out where the hinge would go, drilled and tapped with a 4mm tape and attached the hinge using 4x10mm machine screws. I find it easier to drill, tap and attach the hinge while the bottle is still intact.
Continued on page two…
I started by making all the holes and details in the tank with a 4″ angle grinder. I used cutting discs and a 10mm drill bit to get the perfect results. It was a little tedious, but it was worth it in the end.
I drilled several holes around the bottom of the bottle so air will circulate and help the fire to burn.
Weld everything.
I gave my Vader log burner 2 coats of ultra-high temp black spray paint which finished it off a treat. I’m so glad I decided to go with this colour because it really makes the log burner stand out. Plus, it’s ultra-high temp so it can withstand any heat that comes its way!
Thanks to
Safety Tips for Building and Using a Darth Vader Wood Burner
Building a Darth Vader wood burner is an exciting DIY project. But working with metal, gas bottles, and fire comes with serious risks. Safety should always be your top priority, both during the build and when using the burner. Here’s what you need to know to keep yourself and others safe.
Start with an Empty and Safe Gas Bottle
Before anything else, make sure your gas bottle is completely empty. This step can’t be rushed. Even if it feels empty, leftover gas can still be dangerous. Remove the valve and fill the bottle with water to flush out any remaining gas. This displaces any flammable vapors and makes it safer to work with.
Work in a Well-Ventilated Area
Metalworking creates fumes and sparks. You should work outdoors or in a well-ventilated space like a large shed with open doors and windows. Make sure you’re not near anything flammable, including dry grass, wood piles, or fuel containers.
Wear Proper Safety Gear
Personal protective equipment (PPE) is non-negotiable. Wear a welding helmet or safety goggles, heavy-duty gloves, and a long-sleeve fire-resistant jacket. Ear protection is also a smart move when using an angle grinder. Always wear steel-toe boots to protect your feet from falling metal pieces.
Use the Right Tools for the Job
Angle grinders, drills, and welding machines should be in good working condition. Check that cords are intact and cutting discs aren’t worn out or cracked. Dull or damaged tools are dangerous because they can fail while you’re using them.
Be Careful with Cutting and Grinding
Cutting into metal creates sparks and flying shards. Keep your hands steady and secure the gas bottle to prevent movement while cutting. Never rush the process. It’s better to take your time than risk a slip with a cutting disc.
Ensure Strong and Safe Welds
Welding is what holds your Darth Vader wood burner together. Weak or rushed welds can fail once the burner heats up. Take the time to make solid welds, and double-check all connections before you light the burner for the first time.
Use High-Temperature Paint Safely
When it comes time to paint, make sure you use spray paint that’s rated for ultra-high temperatures. Always paint in an open area away from open flames, and wear a respirator to avoid breathing in fumes.
Position Your Wood Burner Safely
Once your Darth Vader wood burner is complete, place it on a flat, fireproof surface like gravel, concrete, or pavers. Never place it directly on grass or a wooden deck. Keep it a safe distance from fences, walls, and any overhanging trees or structures.
Never Leave It Unattended
Any wood burner, no matter how well-built, needs to be supervised while in use. Never leave it burning unattended. Make sure you have a fire extinguisher or a bucket of sand or water nearby just in case.
Cool Down and Clean Properly
After each use, allow the burner to cool completely before you move or clean it. Dispose of ashes safely in a metal container. Regular cleaning keeps airflow clear and helps your burner perform better.
Building a Darth Vader wood burner is a project that blends craftsmanship with fandom. Just make sure you keep safety at the core of every step. It’ll keep the experience fun and worry-free.
Darth Vader Wood Burner Design Ideas and Variations
A Darth Vader wood burner already makes a bold statement. But with a little creativity, you can take the design even further. Whether you want to make your burner more functional, more detailed, or give it a different Star Wars twist, there are plenty of ways to customize it. Here are some ideas and variations to help inspire your next project.
Classic Darth Vader Helmet with Extra Details
The classic Darth Vader helmet design is always a fan favorite. You can enhance the look by adding more detailed features. For example, you can cut finer lines into the mouthpiece grill or add layered metal plates to create depth in the face mask. Welding small pieces of scrap metal for the eyebrows or adding curved metal for the helmet dome can make it more three-dimensional. You can even use a mesh screen behind the eye holes to add safety while keeping the menacing look.
Glowing Red Eyes and Light Effects
A cool feature to consider is giving your Darth Vader wood burner glowing red eyes. This can be done by placing heat-resistant red glass or metal mesh painted with high-temp red paint behind the eye openings. When the fire burns inside, the glow creates an eerie effect. Some builders also add LED lights for additional glow when the burner isn’t lit. Just make sure the lights are heat-safe or removable if you go that route.
Multi-Function Darth Vader Wood Burner and BBQ Grill
If you enjoy outdoor cooking, you can combine your Darth Vader wood burner with a BBQ grill. Add a removable grill rack inside or on top. Design the helmet so the dome opens like a lid to expose the grill area. This variation makes the burner a functional centerpiece for backyard gatherings. Just be sure to use food-safe grill materials and keep the design practical for cooking.
Miniature Versions for Smaller Spaces
Not everyone has space for a full-size wood burner. If you want a more compact version, consider making a mini Darth Vader burner. Use a smaller gas bottle or a steel cylinder to create a tabletop fire pit. These are great for patios or camping trips. They offer the same great look without taking up too much space.
Stormtrooper and Other Star Wars Character Burners
You don’t have to stop at Darth Vader. Once you get the hang of building one character design, you can expand into other Star Wars themes. Stormtrooper helmets are a popular choice because of their distinct shape and bold design. Boba Fett and The Mandalorian offer even more possibilities with their unique armor details and visors. You can even create a whole set and make your backyard feel like a Star Wars campfire scene.
Themed Paint and Finishes
Color can take your design up a notch. Ultra-high-temp black paint is standard, but you can experiment with metallic finishes to give your wood burner a more armored look. You could also weather the paint to make it appear battle-worn. For an extra pop, add small emblems or stencils of the Galactic Empire logo in high-temp silver or red.
Custom Stands and Bases
A sturdy stand completes the design. You can weld a custom base that looks like part of the Death Star or use scrap metal to create claw-like feet. The stand not only makes your burner safer by elevating it from the ground but also adds a finished, professional look.
With these ideas and variations, your Darth Vader wood burner can be as unique as your imagination allows. Whether you keep it classic or go all out with custom features, it’ll be a conversation starter every time you light it up.
Conclusion
Building a Darth Vader wood burner is a rewarding project for any Star Wars fan or DIY enthusiast. It combines metalworking skills with creative design, resulting in a functional piece of art. Just remember to follow safety guidelines so you can enjoy your unique log burner for years to come.
