If you follow my blog, you’ll know I love creating projects from recycled materials, and this time I’m sharing a DIY Upcycled Aluminium Can Wall Hanging that transforms empty Pepsi Max cans into embossed metal panel art. By using an embossing folder, pop rivets and a simple wooden frame, you’ll end up with a striking, interchangeable wall display that you can rearrange whenever you fancy a fresh look.

I’m thrilled to be taking part in this week’s International Bloggers Club (IBC) challenge, themed “I Can Upcycle,” where we’ll be transforming ordinary cans into something extraordinary. Stay tuned for more about IBC at the end of this post!

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DIY Upcycled Aluminium Can Wall Hanging: Embossed Metal Panel Art

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Materials Needed

• Empty aluminium cans (standard and “mother” size)
• Embossing folder ( your Choice)
• Embossing machine (or rolling pin/primitive method)
• Plywood boards cut to: 1×690 × 120 mm, 2×690 × 80 mm, 4×140 × 140 mm
• Stanley knife, scissors, cutting mat, ruler
• Pop rivet gun and small pop rivets
• Black matte spray paint
• Copper and silver wax paste
• Clear spray polyurethane
• Wood strips (20 mm×10 mm) for the frame
• Wood glue and nail gun, or clamps
• Protective gloves and eyewear

Cutting the Aluminium Cans

Wearing gloves, use a Stanley knife to puncture the top of each can and slide in scissors to remove the lid.

Rinse and dry the can, then cut vertically along the text line to get two clean edges.

Finally, trim off the base with scissors to create a flat sheet.

This was not enough cans for my project because I kept changing my mind, so you will need more.

Trimming Edges for Uniform Panels

Place the cut sheets on a cutting mat, align a ruler along one long edge and trim with a Stanley knife for consistency.

Repeat on the opposite side so every panel measures the same width, which makes alignment on the plywood straightforward.

Embossing the Metal Sheets

Position each aluminium sheet in the embossing folder, silver side up, keeping orientation consistent for a uniform pattern. Roll through an embossing machine; if you don’t have one, press with a rolling pin or carefully stand on the folder on a clean surface.

Trim any excess around the embossed design for future use.

Attaching Sheets to Plywood Bases

Before I added the cans to the wood, I did a test run first and found that plywood worked better.  It was softer than wood, which allowed the pop rivets to embed into the back of the wood. You can glue the cans into place if you don’t want to add pop rivets.   I cut the plywood to the following sizes.

• 1 x 690mm x 120mm
• 2 x 690mm x 80mm
• 4 x 140mm x 140mm

Arrange a sheet on each plywood panel, drill through both layers at the corners, and secure with small pop rivets. The rivets will embed into the softer plywood. Trim any overhang with scissors to achieve neat edges.

I opted for the smallest pop rivets available, as they’re much easier to install.

As I set each pop rivet, it pulled itself firmly into the back of the timber, securing the panels in place. Work your way across, aligning the embossed patterns as you go for a seamless look. I did have to trim a few panels with scissors for a perfect fit—note to self: always slide a scrap piece of wood under your work to protect the table (lucky this was my workshop bench!).

Once all the panels are fixed to the wood, your project should look like the image below.

Painting and Wax Finishing

Spray two even coats of black matte paint over each panel, allowing full drying between coats.

Use copper and silver wax paste to highlight raised sections.

Dip your fingertip and gently rub over the embossing, leaving some black exposed. Let the wax cure for 12 hours.

If you don’t have wax paste on hand, you might already have the ingredients to make your own—give this simple recipe a go.

Sealing and Protecting

Apply two coats of clear spray polyurethane over the waxed panels to prevent dulling over time. Hold the can about 20 cm away and spray in light, even strokes.

Here’s the back view, showing the pop rivets pulled into the plywood.

This is where I originally stopped, but when I reviewed the photos, the panels looked unfinished.

Building and Attaching the Frame

Cut wood strips to frame the assembled panels, paint them black, then glue and nail (or clamp) them into place.

The simple black frame gives the wall hanging a finished look.

Displaying Your Wall Hanging

Mix and match the panel sizes on your wall to create dynamic layouts—horizontal, vertical or staggered. Use removable picture hooks or command strips to affix each panel securely.

Here are a few layout variations you can create.

More Aluminium Can Projects

This wasn’t my first aluminium-can art project—I’d already used the same embossing and riveting technique to build a steampunk mannequin.

Another piece I made is this aluminium-can wall art, which shimmers and gently jingles as it sways in the breeze.

More about IBC

If you follow my blog, you will know I am part of the IBC (International Bloggers Club), which is a group of talented bloggers from around the world. We have members from Spain, South Africa, Australia, the United States, and Canada. Each month, we come together and create a project with a common theme.

If you missed last month’s “Painted furniflips ” theme, here is the link to my Marilyn Monroe decoupage Dresser.  The “I can upcycle” contributions from my fellow bloggers for this month’s challenge are listed below. Please feel free to jump over and give them some love.

1. Me
2. A Crafty Mix|Upcycled tin can pull toy llama
3. Meegan Makes| Diy moss candle holders or vases made from tin cans
4. Birdz of a feather |Can craft
5. Interior Frugalista|Upcycled tin can wind chimes

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