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Drink Can Tinworkby Mangetout on October 31, 2010

Table of Contents

Drink Can Tinwork .............................................................................................................

Intro: Drink Can Tinwork .....................................................................................................

Step 1: Clean off the paint ....................................................................................................

Step 2: Cut the can open .....................................................................................................

Step 3: Tape the metal to a slightly springy board ..................................................................................

Step 4: Mark out the net of the box .............................................................................................

Step 5: Inscribe patterns in the top and sides ......................................................................................

Step 6: Outline the raised pattern ..............................................................................................

Step 7: Re-impress the original embossed pattern ..................................................................................

Step 8: Cut off the waste material ..............................................................................................

Step 9: Scribe the corner pieces ...............................................................................................

Step 10: Fold along the creases to form the box ....................................................................................

Step 11: Fold in the tabs .....................................................................................................

Step 12: Make more boxes ...................................................................................................

Related Instructables ........................................................................................................

Comments ................................................................................................................ 1

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Intro: Drink Can TinworkHow to transform an aluminium drink can into a charming little embossed metal box.

Here's the video version of the instructions:

Step 1: Clean off the paintUsing abrasive paper and/or steel wool, rub off the paint/printing on the outside the can. This doesn't have to be perfect, as tthis will be the inner surface of the finishedbox.

However, skipping this step altogether makes it quite hard to see what you're doing in subsequent steps.

By far the easiest time to do this is when the can is still full and sealed, because the liquid inside will support the walls as you press on them with the abrasive.

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Step 2: Cut the can openEmpty out the can contents and using a sharp pair of scissors, cut around the top, down one side and around the bottom.

This should leave you with a rectangle-shaped piece of thin metal.

The edges may be incredibly sharp and jagged. Please be really careful!

Trim off the jagged edges of the rectangle, but try not to remove too much material.

Image Notes1. Puncture the can with the point of the scissors, then cut around the top, justbelow the 'shoulder'

Image Notes1. These edges are really jagged and sharp - be careful!

Image Notes1. Trim off the jagged edges, but remove as little material as possible in doingthis

Step 3: Tape the metal to a slightly springy boardTape the metal down flat to a stiff surface that has a little bit of yield in it. This could be a piece of stout cardboard, but I used the cork back of a dining table mat.

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Step 4: Mark out the net of the boxUsing a stout ballpoint pen and a straight edge, firmly inscribe lines into the metal

- starting with a two-inch square right in the middle, then a four-inch square surrounding it, followed by another (approx) 5 inch square surrounding that.

Extend the lines right off the edge of the metal in both directions - when you're done, you should end up with a quite complicated-looking grid pattern (take a look at thepictures for details).

The above dimensions are based on a tall 440ml can - if you're starting with a smaller one, you might need to scale things down to fit the available materials

Image Notes

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1. This will be the top of the box2. This will be one of the sides of the box3. This will be a tab that folds over inside the box4. This corner piece will fold inside the box and disappear

Step 5: Inscribe patterns in the top and sidesAgain, using the ballpoint pen, inscribe patterns on the top and side sections of the box - you can do this freehand for curly or organic shapes, or use a straight edge oreven a stencil for geometric ones.

You can even do lettering, but as this will be the inside surface of the box, you'll need to write it backwards.

Step 6: Outline the raised patternRemove the tape securing the metal - now that it's embossed, it should stay pretty nuch flat all on its own.

Turn it over so you're working on the side with the raised pattern.

Using the ballpoint pen, inscribe a line around the inside and outside edge of all the raised patterns.This takes quite a while and seems laborious, but it's worth it in the end, so keep going...

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Image Notes1. A line has been inscribed around the inside and outside edges of this raiseddiamond shape.

Step 7: Re-impress the original embossed patternTurn the metal over again, so you're working on the inscribed side.

With the ballpoint pen, firmly retrace the entire original pattern.

This process of inscribing, outlining, then re-inscribing the pattern creates a much sharper relief for the box decoration.

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Step 8: Cut off the waste material

Step 9: Scribe the corner piecesTurn the metal over so you are working on the raised pattern side.

Using the ballpoint pen and a straight edge, inscribe diagonal lines into each of the corner pieces, running out radially from the centre.

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Step 10: Fold along the creases to form the boxFold the metal to start forming the box - the inscribed lines box should fold naturally in their own correct directions.

The diagonal corners fold inwards as the sides fold down.

Once the sides are folded to an angle of 90 degrees vs the top, the folded-in corner pieces can be pinched flat and pressed in pairs against the inside.

Image Notes1. These lines were inscribed from the visible side, causing them to fold this way2. The corners were inscribed from the opposite side of the metal - they fold theopposite way to the other lines, allowing them to tuck in

Image Notes1. These are the folded-in corner pieces

Step 11: Fold in the tabsFold the small tabs inwards along all sides, starting with the sides against which the folded-in corner pieces had been pressed.

This performs two functions - the folded tab secures the corner pieces in place, holding the box together, but also, the folded edge means the finished box should have noexposed sharp edges.

Repeat for all four tabs and the box is finished.

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Comments

50 comments Add Comment view all 90 comments

alibabbarudolph says: Feb 3, 2011. 5:46 PM REPgreat video and instructable ill be sure to give this a try

DucttapeNinja says: Nov 4, 2010. 1:04 PM REPThis project is made of win....also aluminum.

PRockGirlScout says: Nov 6, 2010. 1:52 PM REPHaha, indeed. So awesome. I can't wait to try this on all sorts of things. I'm thinking little pieces embossed with patterns, then incorporated intowristbands or other accessories would be very cool.

Mangetout says: Nov 6, 2010. 3:47 PM REPI'm thinking of doing home made Christmas cards with a card-framed embossed metal front face.

PRockGirlScout says: Nov 7, 2010. 11:53 AM REPOoh, and ornaments!

Mangetout says: Nov 7, 2010. 2:29 PM REPI'm working on a prototype for a star-shaped box - the interesting thing is that the geometry of the internal corner on the lid causes the pointsto be pulled downwards, giving the thing a sort of domed shape.

naty23bb says: Jan 21, 2011. 12:21 PM REPHi, I love it, nice work

Eye Poker says: Nov 19, 2010. 8:54 PM REPElder Sign!

555mst555 says: Jan 10, 2011. 1:45 AM REPHi, i i'm gonna do this for my brother's birthday coz he likes boxes. In fact, I have already made one side of the box already ( the top part ). and the mainsquare on it is 2 1/4". what do you think should the other side of the box be?

sikamikan says: Nov 26, 2010. 10:55 AM REPgreat work man!

Monidaris says: Nov 26, 2010. 8:44 AM REPHi.This is a wonsderfull tutorial.Thank you so much!Monica

agis68 says: Nov 11, 2010. 1:37 AM REPGreat Idea, beautiful result. 5/5 and more. My wife loves tiny tin boxes and makes also collection... now she collect mine unique models....thnx Mangetout forthis instructable

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boudewijnchill says: Nov 9, 2010. 10:47 AM REPawesome project! just made my own and it turned out beautify

Dreistein says: Nov 8, 2010. 12:44 AM REPin cape town we don't have altoids tins so i will make this

ladycroft108 says: Nov 7, 2010. 5:17 PM REPCool! I've been using this trick (pop cans) to make earrings for a while, never thought of using cans for a box though! I usually paint the pattern with nailpolish then sand it off. it looks like faded lacquer :)

merillo5 says: Nov 7, 2010. 11:38 AM REPWOW ! This is an awesome idea and I can't wait to try it with my 10 year old grandson. I.m thinking belt buckles.

SpinWard says: Nov 7, 2010. 6:22 AM REPBeautiful! Great job!

RaNDoMLeiGH says: Nov 6, 2010. 6:07 PM REPif you want a larger size, you can buy rolls of aluminum flashing in the gutter/roofing section of the hardware store.

Old newspapers or mouse pads make good surfaces for the line work.

I've seen coasters done with this technique. Before mounting the design to a piece of scrap tagboard or whatever you use as the base, pour in a little plasteror grout so the design doesn't get smooshed down.

Someone suggested sharpies for coloring. Alcohol inks and nail polish also make good coloring agents. If you manage to overpaint the raised area, you caneasily remove the color by sanding with a fine grit emery board.

Someone asked about popsicle sticks -- this is a good tool if you want to raise a larger area, such as if you want to make a dome. they really aren't sharpenough for the linework though. Tools like this might work:

http://www.jewelrysupply.com/product/FM2079.html?catPath=272_2315

But everyone has a biro that doesn't write anymore, so it gives you a chance to reuse that too.

If you are going to do a lot of work in the center part you might want to do that before making the marks for the rest of the box. Working metal expands it, andit can throw off your shape.

These make nice little earrings and window dangles and christmas ornaments, too.

Nice instructable!

kingalexl says: Nov 6, 2010. 9:07 AM REPwould it be easier to cut with an exacto knife or utility knife than with scissors?

Mangetout says: Nov 6, 2010. 3:51 PM REPPossibly. Or a dremel with a wheel, but as long as the scissors are sharp, it's not too bad - the main problem is just that the way the scissor blades crossmakes the cut tend to swerve down the can when cutting off the top - actually, if I cut in the other direction (holding the lid in my left hand) the cut isn'tquite so jagged.

twighahn says: Nov 6, 2010. 1:45 PM REPyou know your project is agreat idea when it inspires other ideas

twighahn says: Nov 4, 2010. 3:20 PM REPyour design makes it easy to make boxes of any shape cept round

Bosun Rick says: Nov 5, 2010. 10:10 PM REPYou might be able to make a round one!

After removing the paint, just cut the top off of the can as shown in the instructable, leave the bottom intact.

Then do your pattern work from inside (or outside) of the can.You might have to develop some special tools to accomplish this, but it would be cool!

Just be sure to support the surrounding metal to prevent crushing or tearing it.

Use the bottom of another can that is stretched from the inside to form a cap/lid.

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I have used a Zippo lighter to smooth out the metal for similar projects "Back in the Day" when I smoked, and had a lot of aluminum cans available. (winkwink).

twighahn says: Nov 6, 2010. 1:44 PM REPthere are cans of various sizes too.

twighahn says: Nov 6, 2010. 1:43 PM REPgood idea

Mangetout says: Nov 4, 2010. 4:30 PM REPI reckon even round might be possible, if fluted sides are acceptable. The metal might need to be annealed before it will take that much working though.

Harry8D says: Nov 5, 2010. 3:29 PM REPThis is amazing well done, i love drawing patterns and willl be in a state of euphoria doing this :D i'll post up my results and credit you fully. Thanks alot

Harry

Kryptonite says: Nov 5, 2010. 1:18 AM REPNice job on the embossing, I wouldn't have had the foggiest idea as to how, but you've really covered this well!

paleotool says: Nov 1, 2010. 3:59 PM REPThis is great! I've never really thought of using old cans much but now I will be heading out to buy some beer (in cans).

I can envision making a "tin work" type ceiling or wall splash like this.

SandLizard says: Nov 4, 2010. 11:32 AM REPFor the ceiling or wall splash, if you want the same pattern on each tile, you might try making a mold of the pattern in some kind of press. Then just presseach piece in it to do the embossing. Not sure just how to do that but thought I'd suggest it anyway.

Mangetout says: Nov 5, 2010. 1:13 AM REPOne way that might work: create the pattern out of bent brass or steel wire (soldered if necessary), then lay this flat on a flat surface (ideallysomething like an anvil equivalent), lay the metal flat on top, then hammer it with a rubber mallet to make the metal conform to the wire pattern.

twighahn says: Nov 4, 2010. 2:55 PM REPi could use origami designs to make boxes.great ideas

Mangetout says: Nov 5, 2010. 1:04 AM REPIf your origami designs involve creasing, then unfolding, you might need to anneal the aluminium - I find it typically folds once along any given line, thensnaps if you try to unfold that crease.Heating it in a really hot oven, then allowing to cool slowly should make the metal easier to handle and fold (and can be repeated if it starts to work-harden)

sparkleponytx says: Nov 4, 2010. 11:56 PM REPVery nice Instructable! I have done a little crafting with aluminum cans too. Couple suggestions--you can use an orange stick (the small wooden sticks usedfor manicures) to do the engraving. The wooden point doesn't scratch the metal like the ball point pen and well, it just feels better to work with the wood onmetal vs metal against metal.

Also, to decorate, you can use colored Sharpie pens. The ink in a Sharpie will stay on metal. I have some shiny permanent marker pens which when usedmakes the metal tinted and looks awesome.

Lastly, if you have access to a manual die cut machine, like a Cuttlebug or Sizzix, you can use them on the flattened sheets of aluminum, both to cut shapes

and to emboss. You can find these machines, die cuts and embossing folders really cheap on Craigslist or other places now because everyone is going hightech with the Cricut machine.

The embossing folders which come with the low tech die cut machines let you do all kinds of awesome designs quickly and easily on the aluminum sheets.Maybe I'll do an Instructable sometime of my aluminum can bookmarkers to demonstrate the how-to.

Anyway, again, very nice Instructable and video.

paqrat says: Nov 4, 2010. 10:00 PM REPGreat instructable, great video of it. Not too long ago I found an article in an old school shop magazine on making a small metal box but it required a metalbrake and solder. This is so much more simple but looks so much better. I was very pleasantly surprised to find that the aluminum embosses so well. Forthose who want a bit more contrast they could take some flat black spray paint, spray the box then wipe off the paint. With a little practice you can controlpretty well how much paint you remove. Personally I'd practice on a few flat pieces of embossed metal first.

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ubercop says: Nov 4, 2010. 5:14 PM REPbravo!

edsternet says: Nov 4, 2010. 11:16 AM REPFantastic easy but stylish instructable. Your snowflake version on your website also needs to be checked out. Now where are those beer tins!

Eddie

twighahn says: Nov 4, 2010. 3:21 PM REPa bit of solder on the edges of a wind chime piece

twighahn says: Nov 4, 2010. 3:02 PM REPgives me an idea for wind chimes

Mangetout says: Nov 4, 2010. 12:20 PM REPThanks. I'm just delighted at all the positive feedback here.

Here's the hexagonal version. More variations are also on the drawing board...

Eye Poker says: Nov 19, 2010. 8:35 PM REPI soooooo need the plans for this one.

edsternet says: Nov 20, 2010. 4:38 AM REPThe plan is on the website, over on the right hand sid. Check i t out. http://www.atomicshrimp.com/st/content/drink_can_tinwork_3/

twighahn says: Nov 4, 2010. 3:17 PM REPi have a number of quotations and verses i'd like to emboss and frame

tubanator-2.0 says: Nov 1, 2010. 7:20 PM REPi just finished mine and it is honestly the coolest thing ever.i almost didnt do the extra outlining. but you can use it to get some cool effects.

twighahn says: Nov 4, 2010. 3:03 PM REPembossing polish and a frame...

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Mangetout says: Nov 3, 2010. 1:17 AM REPThe outlining really is a chore, I was in two minds whether to really prescribe it, but it makes such a difference to the relief of the finished pattern than it'sworth the effort.

There's an example of an early prototype made without the outlining and re-impressing on my web page (http://www.atomicshrimp.com/st/content/drink_can_tinwork ) - by comparison, it looks half-made.

The other good thing is that if you work with a black ballpoint pen, the ink that adheres to the metal can end up adding a sort of antique effect.

twighahn says: Nov 4, 2010. 3:04 PM REPi could trace a photo onto a can and frame it

tubanator-2.0 says: Nov 3, 2010. 10:51 AM REPGood idea on the black pen. I used blue and it made it look really weird. Also since i used a stencil i found you have to press really hard otherwise itcan be hard to see some of the complicated parts.

D00M99 says: Nov 1, 2010. 9:01 PM REPNice.

twighahn says: Nov 4, 2010. 3:00 PM REPone couold use this to put presents in then the reciever would get two gifts or a way to store the inside gift.if i were to give an appliance i would use a largerpiece of sheet metal but i think it would be nice to have a way to store the gift on the counter in a decorative box.these could also be used to store coffee andsuch to keep the mice out.i will have to do some thinking about bugs though. a way to seal the box would be nice

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