Every curve and cut in this Sugar Skull propane tank feels like it has a voice of its own.

The skull, with its delicate roses and intricate patterns, honors the Día de los Muertos spirit, where memory and celebration meet.

Once lit, it turns into a lantern that glows like a guardian, both mysterious and welcoming.

What was once a vessel for fire now becomes a symbol of renewal, showing that even forgotten steel can shine again with character, history, and heart.

Materials Needed

• 1 empty propane tank (20 lb standard size, about 12” diameter × 18” tall)
• 1 stencil or printed Sugar Skull pattern (approx. 10-12” tall design)
• Angle grinder with 4.5” cutting disc
• Plasma cutter or oxy-acetylene torch
• Wire brush attachment or 120-grit sandpaper
• Protective gear: leather gloves, welding goggles, respirator, and apron
• Chalk or permanent marker
• Rust-resistant spray paint or high-heat enamel (optional, 12 oz can)
• 1 LED lantern, string lights, or fire-safe candle insert (3-6” size)

Step-by-step Guide

Step 1: Safety comes first. Make sure your propane tank is completely empty.

You need to remove the valve, fill the tank with soapy water, and let it sit overnight to release any remaining fumes. This step cannot be skipped.

Step 2: Clean the outside of the tank with a wire brush or sandpaper until you’ve removed rust and paint. This gives you a smooth surface to draw on.

Step 3: Place your Sugar Skull stencil on the front. Use chalk or marker to trace eyes, nose, teeth, and floral details. A design about 10-12” tall works well for balance on a standard tank.

Step 4: Start cutting the large openings (like eyes and mouth) with your angle grinder. Then switch to your plasma cutter for roses, swirls, and small details.

Step 5: File down sharp edges with a wire brush attachment or sandpaper. You want it smooth enough that no one can get cut if they touch it.

Step 6: For a rustic look, leave the raw patina as it is. If you prefer something bold, spray with high-heat enamel or metallic paint. Gold or bronze accents make the roses pop beautifully.

Step 7: Add your light source. For indoor use, slip in an LED lantern or string lights. Outdoors, a small fire-safe insert will give you that magical flicker.

Tips:

When I first made one of these, I rushed through the cutting and realized later how much charm comes from patience, each swirl and flower is worth slowing down for.

If you’re working outdoors, try waiting until dusk before lighting it up for the first time. Watching the skull’s face come alive against the twilight feels like a reward for all the effort you’ve put in.