Autumn is my favorite time of the year. The days are getting shorter and the cool, crisp evenings have arrived. Mother nature will soon paint the landscape with brilliant shades of reds, gold and yellows. September and October are harvest time for the end of the season crops. There are many apple harvest festivals in the northeast. An abundance of pumpkins, gourds and indian corn are sold at the local farmers markets. Traditionally, along with fall flowers, hay bales and wreathes, people will decorate their homes using these items.

With Halloween just a month away, the jack o'lantern is a perfect craft project for all ages. I would like to share my method of making a jack o'lantern using a hard-shelled gourd. Gourds have risen in popularity as an art medium. Unlike the pumpkin, the hard- shelled gourd will last for many years.

The hard-shelled gourd takes almost a full year to grow and dry for use. After the gourd dries, it will look moldy or dirty. The gourd must be cleaned before it is ready to carve. One method to clean the gourd is as follows:

• clean gourds with a bleach solution to remove dirt and mildew.
• Mix 1 part bleach to 10 parts water and use a medium bristled brush.
• After cleaning, let stand until fully dry.
• The trick is to submerge the gourd completely in the solution and let soak for a while to loosen the dirt. A heavy duty trash bag can be handy for this.

The easiest way is to buy an already clean, dried gourd that is ready to carve.

List of items you will need to make a gourd jack o'lantern:

•   a clean dried gourd (I prefer kettle gourds)
•   orange and black leather dye
•   light cord and bulb
•   drill, jigsaw, exacto knife
•   1" hole saw
•   5/16" or 1/4" drill bit
•   pencil, and pattern (optional)
•   heavy metal spoon
•   Shellac, Varnish or Polyurethane Sealer

First, choose a pattern or draw a free hand design on the gourd using a pencil. Start by cutting the lid (hat) off so you can clean out the gourd. Use an exacto knife to start a slot that your jigsaw blade will fit through. That way you won't see a hole from a drill bit when you're finished. Insert the jigsaw blade through the slot, and cut by following the lines you drew onto the gourd.

Remove the lid and clean out the gourd with the heavy metal spoon. Try to remove all the pith and seeds. It helps to make some cross cuts into the pith with a knife. Continue cutting out your design with the jigsaw. Drill some holes in the eyes, nose and mouth so you can insert the jig saw blade.

Use a 1" hole saw to drill the hole for the light. Select a spot under the lid in the back, about 1" down from the top of the body, for your hole. If you don't have a 1" hole saw you can use a spade bit. A hole saw makes a much cleaner hole.

Once you've finished with all the cuts, it's time to wipe off the gourd with a damp cloth and start dying. An applicator comes with the 4 oz. bottles of leather dye, however, it's easier with a lambs wool swatch. Use the black leather dye for the hat and orange for the body. The body may take two coats. A 4 oz. bottle of leather dye will do up to 20 jack-o-lanterns. Let the dye dry for a couple hours. Then wipe with a cloth.

Spray the whole gourd with a sealer to protect it from the elements and make it last for many years. I like to use Bullseye Shellac because it sprays on nicely, gives the jack-o-lantern a healthy shine, and it's less expensive than some of the other sealers. Spray polyurethanes also work well if you already have them on hand.

Once the sealer is dry, (about 1 hour for the shellac), insert the light cord by pushing it through the 1" hole until the metal prongs grab the gourd firmly. Screw in the light bulb, plug it in, and admire your gourd jack-o-lantern.

Approximate time to complete the jack o'lantern from start to finish depends on your expertise and type of tools you have available. With the proper tools, you can complete a jack o'lantern from start to finish in approximately one hour. (Using a clean, ready to carve gourd).

Just a note - Do not use candles in this type of jack o'lantern because a dried hard shell gourd will catch on fire and burn.

Enjoy your hard-shelled gourd jack o'lantern for many years. You may have to make some for friends and family too.

Chip Konrad - Chip Konrad is the creator and webmaster of a website devoted entirely to hard shelled gourds. As a member of the Pennsylvania Gourd Society and the American Gourd Society, he is also involved with local organizations to teach gourd art and craft techniques. His partnership with an Amish family in Lancaster County Pennsylvania has enabled them to market their gourds nationwide. Crafters love the dried, clean gourds, low prices, and terrific customer service.   Website: Amish Gourds To review the Reprint Rights for this article, please go to the authors page by clicking the button below.