Step 1: Purchase Materials

The most challenging material to obtain is the stamped tin ceiling panel. Visit local architectural salvage stores and search online. Prices range from $15 to $70 per panel, based on condition and material.

Old wooden house siding, high tide flotsam or even rough-cut oak or cedar fencing will work to create the rustic appearance. Keep an eye out for old houses being remodeled. The building site burn pile is an excellent location to claim the perfect piece of rough-hewed lumber.

Step 2: Fabricate the Frame

Rip the Frame Width: Based on the intended use of the frame and its dimensions, set the table saw to the desired frame width. Depending on the overall size of the frame, rip enough lumber to accommodate all four sides, with plenty of wood to spare.

Miter Cut the Corners: The frame will consist of four sides connected to make 90-degree corners. Each side of the frame will have the ends miter cut at 45 degrees to make the corners square. Place a framing square or speed square on the corner to confirm 90 degrees.

Making the Frame: Pre-drill the frame corner pieces using a pocket hole jig. Apply heavy-duty construction adhesive to the contact edges. Secure the corners by screwing them together.

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Step 3: Route the Frame

With the frame screwed together, scribe the face in pencil with the desired shape of the imbedded stamped tin. Insert a straight cutting router bit (dado bit) into the router. Clamp the wooden frame onto a solid surface and carefully route out a 1/2" deep pattern for the stamped tin insert. Repeat the routing process on all four faces of the frame.

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