Step 1: Start Off With a Piece of Steel
This 6" piece of 1.25" flat bar stock was provided by Techshop as part of the Basic Metal Shop SBU class.
I used the Horizontal Bandsaw to cut a down a 3ft piece to the usable 6in.
Step 2: Draw Your Pattern
The main idea is drill ~.5in hole and use vertical bandsaw to cut off the pieces you don't need.
Step 3: Drill and Cut
Next use smaller drill bit for a pilot hole. Then drill out using a .5 inch drill bit. Be sure to secure your work to a table or using a drill press will make the job pretty easy.
Next, Using a vertical bandsaw cut off the unwanted pieces. It helps to start with the short cuts so you don't have to back out of a long cut.
Step 4: Start to Shape It
You could stop here and have a usable bottle opener for the tool box or garage....
I on the other hand wanted to shape it a little more.
Read on to see more.
Step 5: Finishing Touches
After that I used a rotary tool (Dremel) with some smaller sanding attachments to shape the hard to reach places.
I also decided to put a little shine on it, using a buffing pad attachment and some polishing compound.
I know I could have done it differently by using a series of different grit sand paper progressively getting finer and I could have have gotten a nice mirror finish on it.