Aluminum Bottle Tumbler Cup & Cook Pot for an Alcohol Stove

Picture of Aluminum Bottle Tumbler Cup & Cook Pot for an Alcohol Stove
Roll a rim on an Aluminum Bottle to create a Tumbler Cup, or a Cook Pot for a backpacking stove.

This instructable walks through the process of making a mouth-friendly edge on an aluminum bottle turning it into a Cool Reusable Metal Tumbler Cup.

The steps outlined here are, stand-alone, instructions to make a complete Metal Tumber from an aluminum bottle; suitable to use as a lightweight tankard for all your favorite beverages.
(I recommend the chilled kind. Remember science?...aluminum is an excellent heat conductor; you don't want hot cocoa burns on your fingertips as well as the tip of your tongue!)

However... those of you familiar with the Aluminum Bottle Backpacking Stove,
( ) will also recognize the technique demonstrated here, as a means for creating light weight cooking tools to accompany an alcohol stove.

The video below shows these Aluminum Bottles & Tumblers in use as a lightweight backpacking cook / storage system.

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Step 1:

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I have gotten inquires about the availability of this style aluminum bottle.
The bottles are obviously used for beer (and I know at least one soft drink) however, availability of either (or any for that matter) varies by region.

As an added note: I had reservation about posting an instructable that featured an alcohol container as it is not appropriate for all. I would have perfered to use a soft drink bottle however due to availability in my area, I only have found the beer bottle variety.
But ultimately, its the aluminum bottle that we're interested in, not necessarly the beverage. Dispose of the contents as you deem appropriate, or seek out empties through another source.

(Along the same lines: I am pretty sure not everyone who has built a bar-b-que from a steel barrel personally bought, and consumed the 50 gallons of Crude Oil inside to get to an empty drum.)
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These are awesome!!! But you shouldn't cook in them, aluminum gives off really bad chemicals when heated. But still they are awesome and are probably fine for occasional use!!
incredible, I thought you would need to fire the rim first, it might even be helpful. I wish I had gotten into making these BEFORE the bottles became extinct! 

can't really get them  here on LI w/o extreme expense, and if you do not like Bud, (me), or can't drink anymore anyway , (me) , then y'all screwed. I would love to try this out . Anyone out there know of any place out here that sell it on premise , so I could try to scrounge them ??


In Pennsylvania I first saw the aluminum bottles at the local bar for a special event. Mostly I don't see them at the bar but now the beer distributer sells Bud alum. bottles by the case. I suggest checking at your local drinking establishments, that is if you're still allowed to enter.
Hi Limb Reaper, DAD BURNIT IT! I found your reply the day I got back from Pennsylvannia !! AARRGGHH I even passed two beer distributors. I gotta say I hate Budweiser so I would never have bought the stuff, do they have Deposit bottles there? sparkie
Ha, I'm hot a big Bud fan either. No we don't have any deposits in my area North of Pittsburgh. I suggest buying a case and gifting it on the condition that the receiver returns the bottles to you.
I did almost this very thing.

Having wanted the bottles for awhile to make the various Ible goodies, I finally found them at the local Safeway.

Bought a case for our anniversary BBQ and just told everyone to put the bottles back into the box when they were empty.

Still got a bottle sitting in my fridge waiting for someone with different tastes to visit, but I got my bottles. :D
By next year I am told Dinkle Acker will re debut here in cans, but drinkable beer/pilsner
Wow! This was such an old post I almost forgot about it. I haven't messed with the stoves for a while. My design ideas ran their course I guess. I'm still sitting on a handful of the good bottles just in case though :-)
Wow! This was such an old post I almost forgot about it. I haven't messed with the stoves for a while. My design ideas ran their course I guess. I'm still sitting on a handful of the good bottles just in case though :-)
Hi, Good Idea, gone flat. Anybody I know that I would willingly give a caser of beer to (at a very high price), would not be caught dead with a Bud in their hands. All of us drink german stuff. This week a big special by us is buy a case of Hoffbrau October fest, get a 1 liter Stein (glass, not clay :-( ) free. I have two now, (or soon will, they owe me one). I may buy a few (if I can find them) and just dump them out. I can drink maybe two then they destroy me, bad hamngover or futzie head next day. Drink the Deutch stuff, no worries. I just wish I had gotten your email B$ I left PA , I passed two beer distributors on way home. Of course in PA one must buy "cases" from a beer distributor, here in NY it is wacko, but I can buy onsies and twosies in a BD. ttfn sparkie
JoshuaSmock3 years ago
Venom Energy drinks come in thick aluminum bottles, as a non-alcoholic alternative, also it's made by Dr Pepper Snapple so it's widely available.
Venom are one of my preferred crafting bottles as well. The resealable top is a huge plus. And they aren't as narrow as the beer bottles.

However the bottle is not nearly as sturdy as the Bud and Coke bottles. Also, and this is my main reason for seeking out other sources than Venom, they do not have a bottom shape that allows them to be used effectively as a die.
tinkrtur12 years ago
I contacted Budweiser HQ and gave them my zip code. They provided me with the names of places to purchase their beer in my local area. You might want to try the same with coca-cola, pepsi-co, coors, etc.
AbbieX2 years ago
Dollar Tree sells cheapo aluminum water "bottles" guessed it...$1! Yeah, I would rather go this route than to choke down a budmiloors!
a few matching pairs of these would make a great inexpensive wedding present if you have friends that are big drinkers. We have friend who are HUGE drinkers and wish I could have made them some for their recent wedding.
nodnol5 years ago
What kind of lining is in the aluminum bottle? Doctors and food safety specialists often say not to store food or beverages in opened aluminum containers, or re-use the containers because the aluminum may leach out. Aluminum consumption is linked to Alzheimer's Disease. However, if the bottle has a protective lining, it should be ok to re-use.
hpstoutharrow (author)  nodnol5 years ago
I believe most metal food and beverage containers are sprayed with a food grade epoxy coating to prevent contact (and chemical reactions) between the food and metal.
Some cans are lined with BPA. The use of BPA has become a huge debate. The food packaging industry is clearly for the use of BPA as it does exactly what you two are stating, however the flip side of the debate mothers, doctors have begun to voice their experiences with it. Canada has begun to ban the chemical in all food grade containers. It's sad to come to know that since a lot of things in this world can cause cancer, it would be extremely difficult to stay away from everything that is "cancer causing." I'm against BPA use, but I am TOTALLY for these aluminum tumblers!!! Good job, I've always wanted to know how to roll an aluminum lip like that!
My understanding is that the entire industry is phasing out that type of plastic liner for all types of cans. I think I saw a news story on that only a few weeks ago.
jaberwok325 years ago
hpstoutharrow ,  I think your instruckable is fantastic.  I made the backpackstove, it works great.  I have a question though, when I try to roll the edge of the tumbler, I get to the point when you work it on the wood, the lip is beveled out flat and when I start the rolling over process on the first roll I constantly get a crack .  Im having trouble getting the first roll to lay flat against the can.  Ive tried so much my fiance is beginging to think Im an Alcoholic.  Lol   Am I putting too much pressure? Going to fast?  If you could enlighten me that would be great.   Im sure your an expert and these are just amature mistakes but I would really like a tumbler set lol.
hpstoutharrow (author)  jaberwok325 years ago
A few split when I first started. I hope something here helps:
1. Make sure the cut edge is free of saw nicks, burrs, and file marks. There should be no edge imperfections that could initiate a crack.
2. The cut edge should be flat. After any cutting or de-burr filing turn the edge on emery cloth placed on a flat surface. Removing material this way eliminates high spots on the edge and ensures the edge has a full wall stock thickness.
(see the first photo below)
3. When the flare is started make sure the edge is not too wide.
4. When rocking the bottle on the wood to roll the edge, do it gradually and evenly. It will take a number of turns. Periodically stop and examine the edge to make sure it is rolling evenly. Adjust downward pressure accordingly.
5.  Make sure the bottle stays round while rocking the bottle do not apply so much downward force that the edge of the bottle takes on an extreme oval shape. Stop occasionally and use the dowel or push bottle over the neck end of another bottle or use a PVC pipe connector (photo 2 below) to "stretch" the edge back into round.

Good luck and keep trying. Let me know if you succeed.
Ah gee, looking at your pics. I guess I can't add much useful as I too figured out to use the PVC collars also. I can suggest to use the shortened bottom of a "cottle" and a leather mallet to help form an "inside" rolled lip. This works especially well if the bottle bottom is streached first. Also some single use propane cylinders (Worthington brand) when cut open (extreme caution warning: Be certain cylinder is completely empty before cutting open) have a dished bottom wish is handy in forming an internal bead. The "forming" can bottom must have a small hole drilled in it to avoid a vaccum. I hope that's helpful to somebody.
I wouldn't get too excited about posting the "beer bottle" stove since most kiddies know what beer is. I do have to agree with the comments against using the cans as the primary cooking vessel as they certainly are lined (at least the soda cans). With that said; I have thrown caution to the wind and made a coffee percolator from Bud bottles myself.
lostdragon4 years ago
I wouldn't use one of these to cook anything in. They are usually lined with something that isn't made to be heated and you'll end up eating it. Somebody e-mailed Heineken in a different 'ible about making a cook pot out of their beer cans and they replied with as much. Be careful.
They're lined with plastic. Though any that will vaporize will burn off the first time you use it. And you don't eat the flames (I hope).
TANZMEISTER4 years ago
using another bottle as a pot is a neat concept. However, it seems that with the flames racing up the sides your losing at least half your heat to the surrounding system rather then transfering it to your desired heat reservoir (your pot). If having better efficiency is not an issue, then using the bottle as a pot is great. If better efficiency is an issue, then I'd recommend a pot with a larger base, twice the diameter of the heat source is usually recommended for gas camp stoves. your pot design is still the best I've seen here on instructcables!
fail! I ment to say stove design at the end there
Great ible
ch54 years ago
I didn't think that putting such a neat finish on the borders could be done by hand without some kind of weird specific tool.
I'm doing this to my alcohol stoves soon :)

Thanks a lot.

Quite cool.  I wish I had a set of these.
junits155 years ago
what brand of soda uses these?
smn368 junits155 years ago
there were a few limited edition mt dew and other pepsi products that were in the same bottles
junits15 smn3685 years ago
as soon as i read, "limited" i went, DARN
The "Venom"  brand energy drink also uses these bottles.
speaking of the Venom brand, i bought two last night and remember mentioning them here. So, naturally, I followed this instructable lol 
hpstoutharrow (author)  Father Christmas5 years ago
 Nicely done!  The Venom graphic looks great as a cup.
I agree. I am contemplating buying the other flavours just for the purpose of a full set, to give as gifts to those certain people who are obsessed with energy drinks.. 
hpstoutharrow (author)  Father Christmas5 years ago
 I found some Mt. Dew aluminum bottles with Halloween designs this last October.  How's this as an "eye for an eye".   Though I think I like the Venom eye better.

ha! Eye for an Eye! That was pure genius! I never woulda thought of that! :)
hpstoutharrow (author)  junits155 years ago
I received comments there are bottles of Mountain Dew. I have not found them myself.
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