Crazy Christmas Star

This great little project is fun for the experienced and beginner alike and can lend itself to adaptions of your own design!

Skill Level: Beginner/All

Technique: Metal cutting, texturing, wire coiling.

Materials

• 21 Gauge Sheet Metal, 2″ x 2.25″ or Pre-cut Sheet Metal Shapes
• 16 gauge jump ring, 6.0mm I.D
• 18-Guage Wire (approximately 2.5″)

Tools:

• Safety Glasses
• Leather Gloves (optional)
• Metal Shears
• Hand File
• Acrylic Nail File, 240-400 grit
• Metal Stamp
• Hammer
• Steel Block
• Punch Pliers–1.80mm
• Dapping Block–Large Size
• Wooden Punches
• Round Nose Pliers
• Chain Nose Pliers
• Flat Nose Pliers
• Soft Brass Brush
• Polishing Cloth

Instructions:

1. Cut out a paper star pattern with scissors and trace it onto your sheet metal using a permanent marker. Then, using metal shears, cut the star fromthe sheet metal. You can also use a Pre-cut Metal star shape. If so, simply follow the steps for necessary for adding your own designs!

1. Place the star, curved side down, on a steel block. Tap it with a rawhide hammer until it is flat. File the edges of the star with a metal hand file until they are smooth. An acrylic nail file is helpful for a final sanding. Tool Tip: When using a hand file, remember to file in the opposite direction from which the teeth run. That is, make contact with the metal as the file moves away from you, using a pushing motion.

1. Using a metal stamp of your choice, hammer a design into the surface of your metal star. Tool Tip: A dead blow brass hammer works best when striking metal stamps–it is less likely to slip and the weight of the hammer will make your strikes more effective. It is often helpful to practice stamping your design on a scrap piece of metal. Hold the stamp perpendicular to the surface of the metal and strike solidly. It is best to strike once, but you may find it necessary to strike several times. If so, be sure to hold the stamp firmly so that it does not move, making multiple images of your design.

1. Using a soft brass brush, polish the surface of the star, holding it on the steel block as shown. Then, wrap a Polishing Cloth around a flexible acrylic nail file and firmly buff the star to a bright shine with the cloth. Tool Tip: For a high luster and flawless shine, your star may be tumble polished in a Lortone Tumbler with mixed stainless steel shot and a few drops of Super Sunsheen Burnishing Compound.

1. After marking the appropriate place with a permanent marker, use Punch Pliers (1.80mm) to put a hole in the top of the star. Tool Tip: EuroPunch Pliers are ideal for punching a hole in your star. These pliers can easily handle 24-gauge metal while allowing easy placement of the hole in just the right spot. These pliers also come in a 1.25mm size.

1. Place your star with the stamped side down in the hollow of a large, shallow dapping block. Using a wooden punch and hammer as shown in the picture, begin forming the star into a gently curved shape.
   

1. Using Flush Cutters, flush cut one end of a piece of dead soft18-gauge wire. To flush cut, place the flat side of the flush cutter blades toward
   the piece of wire that you want to use and the “v” of the blades toward that wire that you will not use to make the coil.
   

1. Using Round Nose Pliers, begin forming a round coil. Once you have made a complete revolution, gently but firmly hold the loop deep in the
   jaws of your Medium or Wide Flat Nose Pliers and continue coiling for about 2.5 revolutions. Tool Tip: It is important to use only the amount of pressure necessary to hold the wire as you coil it so that marring
   will not occur.
   

1. With your Round Nose Pliers, make the desired number of curves to finish the coil. Lastly, make a loop on the end of the wire so that you can hang the star from a jump ring.
   

1. Connect the coil to the star using a 16-gauge jump ring that is 6.0mm inside diameter. This jump ring will also serve as a bail for hanging the star.

You have  completed the  Crazy Christmas Star!