DIY Corrugated Metal Ceiling: Easy Basement Renovation
Have you browsed those top 10 rustic decor pages but left feeling empty inside? Did you search for how to finish an unfinished basement ceiling but only found the same old paint or drywall solutions? Yeah my feline friend, I am with you. Neither option was appealing to me either. Thankfully, I took a risk on a twist to traditional corrugated sheet metal interior design and am here to share my results with you.
Project Overview
Difficulty Level: Alley Cat (Intermediate)
Time Required: 3-4 hours
Note: Handling corrugated metal requires caution - edges can be extremely sharp
Corrugated Metal Ceiling Transformation Video
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The Problem
Started from the bottom now we here, literally. We started from the bottom with paint and built some really cool things but when we looked up an exposed beam, nail ridden, randomly placed fixtureless lightbulb mess of an unfinished basement ceiling still existed. The internet and all those click bait puppy lovin' "top 10" home design tip websites tried to box me in to painting the beams. While I love a good cardboard box, the metaphorical box of options didn't fit the look that I was going for.
Worse, I could not fathom a way to create even lighting without sacrificing head space. Our basement has relatively low ceilings and learning how to finish a basement with low ceilings was a challenge.
The Solution
I always loved corrugated metal, especially naturally rusted sheets. We have seen interior corrugated metal walls before but never a corrugated metal interior ceiling. The patina is unique and is a great way to add depth and character. The material is thin and doesn't take up a lot of precious head space. This allows us to maximize the ceiling height and makes for a great game of Pop-A-Shot.
Better yet? This project was cheap and EASY. The hardest part was getting the sheets home and into the basement. We put the entire ceiling up in less than an hour. We hope this rustic basement man cave idea works for you!
Artificial Rust Effect (Optional)
If your corrugated metal is too shiny and new, you can create a DIY rust effect:
Peracetic Acid Rust Solution
- Clean the metal sheets to remove any oils or residues
- In a spray bottle, mix two parts hydrogen peroxide, one part vinegar, and a tablespoon of salt
- Spray the solution evenly onto the metal. The chemical reaction will start to create rust
- Allow the metal to dry, and repeat the process to intensify the rust effect
- Once you've achieved the desired level of rust, you can seal the metal with a clear coat to prevent further corrosion (optional)
WARNING: Do this outdoors! The solution will kill grass and plants.
Final Results
Corrugated Metal with Patio Lights
The perfect combination of rustic metal with warm, dimmable patio string lights.
Complete Speakeasy Bar Setup
The corrugated metal ceiling perfectly complements the spalted maple bar and rustic decor.
Tools You'll Need
Tin Snips
For cutting the corrugated metal to size - essential for fitting sheets properly
Nut Driver
Makes installing hex-head roofing screws much easier
Materials Needed
Corrugated Metal Sheets
Source from Facebook Marketplace for affordable, pre-rusted sheets. Typically 26" wide in 8', 10' or 12' lengths
Step-by-Step Instructions
1Source Your Corrugated Metal
Facebook Marketplace is your best bet to find used corrugated metal at affordable prices. Recycling companies often post scrap metal perfect for this project.
The number of panels needed depends on your ceiling square footage. Corrugated metal typically comes 26" wide in lengths of 8', 10', or 12'.
Look for sheets that are solid (no holes) but have a nice patina. Speak with sellers to ensure there are no holes or dangerous rough edges.
2Prepare the Metal (Optional Rust Treatment)
If your sheets need more character, you can create an artificial rust effect. Mix a solution of two parts hydrogen peroxide, one part vinegar, and a tablespoon of salt in a spray bottle.
WARNING: Work outdoors as this process will kill grass. Put on latex gloves and have rags or brushes ready.
Spray the solution on the metal and the rust will begin to form. For existing rusty panels, simply wet and scrub them to spread the rust coloring more evenly across the surface.
3Install the Metal Ceiling
This step requires two people for safety and ease of installation. Wear your cut-resistant gloves!
Using 1" hex head self-sealing screws, drill directly into the corrugated metal and into the ceiling joists. For each six-foot panel, use approximately 6 screws.
Plan to overlap the sheets slightly for a cohesive look. If needed, use tin snips to cut sheets to length, but be extremely careful of the sharp edges created.
4Add Lighting
Govee outdoor patio lights are perfect for this style of ceiling. They're lightweight and can be controlled via app to set the perfect mood lighting.
To mount the lights, install small J-hooks into the metal. A shortcut is to use your drill chuck to hold the hook while you drill it directly into the corrugated metal.
Space the hooks evenly to distribute weight and create a natural flow of lights without looking too structured.
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