Rusted Sheet Metal Wall Covering

12 years ago

I wanted a way to punch up our boring beige TV niche in our living. I wanted something more than just paint. So, I set out to design something with an industrial Steampunk look and feel. I decided on rusted overlapping riveted panels of sheet metal. I started with seven 3’ x 4’ sheets of thin cage metal. I laid the sheets out on a layer of plastic and sprayed them generously muriatic acid. It’s this acid that causes the sheets to rust. I then hung the panel up to allow the acid to dry. The rusting effect took several days to get to build up a patina that I was happy with. Once the panels had the patina, I used an air spray gun to coat the panels with a high gloss oil based polyurethane. I applied three coats of the polyurethane, allowing for each to coat to dry before applying the next. I didn’t want to damage the wall with all the little screws that I was going to be using, so I applied a layer of ¼” plywood to the wall before attaching the metal panels. Because the panels were designed to be overlapped, the project required very little cuts. I tacked up the panels using a small nails. Once the panels were all tacked up I then went around each panel with a line of self tapping screws. I used screws to mimic the look of rivets. I’m very happy with the end result. The next phase of this project is to build a floating media cabinet that will compliment the look of the wall.

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Incite Design

12 years ago

Very creative use of materials - I like the contrast!

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Comments (29)

indianpatti
12 years ago
Very cool .. love it!
riewski thanked indianpatti
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ASVInteriors
12 years ago
Brilliant! Also thanks for the how-to as well - I love this kind of out of the box thinking.
riewski thanked ASVInteriors
riewski
Original Author
12 years ago
Here are a few additional in-progress images of the project. These should provide a good idea of what steps were involved.
m3459
12 years ago
Outstanding....I love the industrial rustic look.
Mark
12 years ago
A job well done, such a dramatic difference you have made. L O V E it !
rosecottagehome
12 years ago
The look is fantastic! I love what you have done and so imaginative. The floating media cabinet will look awesome and complete the look you are going for. GREAT JOB!
riewski thanked rosecottagehome
groveraxle
12 years ago
FAB. U. LOUS!
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Dana Decals
12 years ago
Such a unique look, love it!
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swissmade22
12 years ago
Fantastic idea
riewski thanked swissmade22
riewski
Original Author
12 years ago
No reflection to speak of. You can see a bit of reflection from a few lights in the room, but not much. It being darker actually makes the TV stand out more at night compared to the light background in the before pics.
grobby
12 years ago
Nice. Love the patina.
riewski thanked grobby
Samantha L
12 years ago
Fantastic creative idea!
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Specialty Doors
12 years ago
love it...so unique!
riewski thanked Specialty Doors
User
12 years ago
Good idea.
riewski thanked User
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Sandy G. ltd.
12 years ago
last modified: 12 years ago
- Absolutely incredibly creative!
So refreshing to see someone DIY with such stunning results!
Each panel is frame-able fine art! I want one!
riewski thanked Sandy G. ltd.
condomary
12 years ago
Awesome *****
riewski thanked condomary
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Comwest Construction
12 years ago
Very nice job, looks great
riewski thanked Comwest Construction
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Barnhart Gallery
12 years ago
You are too modest -- check out how you managed to fit that curve. Superb.
riewski thanked Barnhart Gallery
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Tereza & Leigh Ann Hello
12 years ago
Very handsome!!!! Great job!!! I'd love to see this application on the back of an island!!!! Beautiful!
riewski thanked Tereza & Leigh Ann Hello
guydeschamps
12 years ago
Very creative
susan531
10 years ago
Any idea of the total cost for this? I love it.
Architectural Notice
10 years ago
Looks nice.

You are very creative.
PRO
Wise Home + Design
10 years ago
The patina on those metal panels is gorgeous.
speaktodeek
10 years ago
What did you use to rust the panels, and did you put a sealer coat on afterward? Did you just rust the mounting screw heads and leave them visible sort of steam-punky?

This is terrific, it so enhances the niche and really makes your TV space architectural. Can't wait to see the floating media center - post it in this thread so we get the update link in email!
Boomers775
10 years ago
Hope the OP is still around to answer your questions. This post is nearly 2 years old.
riewski
Original Author
10 years ago
"susan531" - The project was pretty reasonable. The metal panels were 48"x36" and cost around $10.00. I used 7 panels, so $70 there; $10.00 for the muriatic acid used to rust the panels; $20 on the wood panels used behind the metal; a few dollars on polyurethane sealer and screws. So, project cost was around $120. I included a link to the metal panels from Home Depot below:

http://www.homedepot.com/p/Master-Flow-24-in-x-36-in-Galvanized-Steel-Flat-Sheet-GFS24X361P/202191776
riewski
Original Author
10 years ago
speaktodeek - I used muriatic acid to rust the panels. A word of caution, it is best to do this part of the project outdoors. I did it in my garage and found it's not only the direct contact of the acid but also the fumes that causes metal to rust. I ended up with layer of rust on a bunch of my tools.
Jill Gutwein
8 years ago
I'm so happy I found your post...even though I know you posted a few years ago! I would like to do a similar idea and wrap the rusted sheet metal around a wood framed fireplace surround. Is the sheet metal bendable? Also how did you attach the TV to the wall through the sheet metal? How is it holding up now that it's been a few years? Thanks and congrats on a beautiful project!
riewski thanked Jill Gutwein