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Signing UpStep 1: Preparing the can
2. Using sharp scissors, poke a hole in the side of the soda can near the top. I usually do this in the nutrition label.
3. Cut all the way around the can and remove the top part of the can.
4. Cut straight down the can through the nutrition label to the bottom of the can.
5. Cut around the can and rmove the bottom part of the can.
6. Trim the edges to remove jagged edges.
7. Flatten the piece of aluminum you have left.









































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When you use a punch to cut soda cans, the edges are not generally sharp, but if you are concerned you can use a nail file block----the one inch square, 3 inch long things in the makeup aisle of pharmacies----to sand the edges. Using an emery board or a bastard file tends to make the edges sharper, I don't know why. Probably something to do with the different size of grit in the block, or maybe its flexibility.
Also you can put a can in a punch like the one shown on the floor, and step on the punch to add some force if necessary. Sometimes my hand strength isn't sufficient to work the punch, and not all cans are the same gage. They are generally also slightly thicker at the bottom of the can.
If you are using a smaller diameter can (like the juice ones) and the roll is too much to get it into the punch jaws, you can iron the can with a regular clothes iron to flatten it. Sandwich your can between towels to protect your worksurface and iron, and use a medium high heat.
Maybe try using the colored side of the can too.