How to Build a Screen Out of Plumbing Pipes and Sheet Metal

Cut four equal lengths of pipe. Dry fit the pipes, using elbow fittings. Check whether the frame is square by measuring the diagonals. If the distance between the opposing angles is the same, all the corners are 90 degrees. Fasten the pipes and fittings. The method of fastening will depend on the type of pipe you use. Prime and cement PVC pieces; screw together threaded metal pipes and fittings. Connect copper pipes easily using quick-connect or push-to-connect fittings. This will create the frame of your screen.

Measure the rough distance between the inside edges of the pipes across the length of the frame. Both length and width will be the same measurement. Adjust the measurement to reflect any gap you prefer between the metal and the frame. This will affect how much wire you need to attach the panels. A greater gap requires more wire.

Mark the measurements onto the sheet-metal panels. Cut the panels to the appropriate size using shears or snips. Run the de-burring tool along the edge to remove any shards. Alternatively, order custom-cut panels or have a hardware store cut the metal.

Punch equally spaced holes along the top and bottom edges of the panels. The size of the die -- and so the holes -- depends on the material you use to attach the panels to the frame. For example, using a thin wire will allow you to punch smaller diameter holes. Thin wire is also easier to manipulate. Opt for smaller holes if you want to disguise the holes or create less opportunities to see through the screen.

Attach the panel to the frame. Lay the frame out on the ground or your work surface. Run one end of a piece of wire through the hole at the top left of the panel, then around the frame. Twist the short end of the wire over and around itself to secure it, using your fingers or pliers. Continue to weave the free end of the wire through the panel and over the frame in the same direction, from the same side each time, as if you are stitching it together. Keep the wire taut, and measure to check that you maintain the same gap between the panel and frame as you work. Cut off any excess length, and twist the wire back on itself to secure it once you reach the end of the panel. Repeat along the bottom edge.