Step 1: Get Your Materials
I resized the image a few times and printed it out. The goal here is to print out a ball the same size as a penny.
To find a pre-1983 penny simply pull out the pennies that are the darkest in the bunch. Of the three I pulled out, two were what I wanted.
Also grab 4 paper clips, some socket bits and, a pair of pliers.
Step 2: Paper Clip Seams
You’ll want to make a series of bends that match the seams of the ball you printed. All I did was use small sockets for the smaller bends and larger sockets for the larger bends.
Use an individual paper clip for each seam. Check the wires against the ball until they match. To help match up the wires to the penny, mark registration lines where they meet the edges of the ball.
Step 3: Emboss
Place a striking tool against the penny / wire and hit that with a heavy hammer. The thick metal rod, I’m using as a striking tool, is from a piece of construction equipment. It’s a pivot pin from a loader bucket.
Repeat the process until all the seams are embossed.
Step 4: Drill Press Mounting
Apply flux to the coin and nail head. Solder and mount it into a drill press.
Step 5: Polish
I started with 100 grit followed by 400, 1000, 2000, and then polishing compound.
Keep the sand paper wet to avoid clogging the paper with copper.
Step 6: Finish Up
Use a black paint pen to fill in the embossed seams, wiping away the excess with a paper napkin.
The tie tack backings are also available at the craft store.
Thanks for reading.