Here's another cool Instructable where I show how you can reuse spent bullet casings and make an awesome pair of cufflinks, which make an excellent Groomsmen or Father's Day gift!
The great thing about this project is that it can be done with simple tools! Take a look at the video to see how I do it. :-)
NOTE: As with other bullet or metal projects, please use PPE (Proper Protective Equipment). You wouldn't want to risk cutting yourself or getting a piece of metal stuck in your eye! Safety first!
Step 1: Materials and Tools
Here are the materials and tools you'll need:
- Two .45 caliber bullet casings
- Two 12 mm cufflink blanks
- E6000 glue
- Tin Snips
- 220 Grit Sandpaper
- Rotary Tool
- Sanding Drum
- Vise or pliers (to grip casing)
- Polishing wheel and compound (optional)
Step 2: Trimming the Bullet Casings
This is a technique I came up with out of necessity because I don't have expensive equipment such as a metal lathe.
Start by cutting into the casing at an angle and keep working your way down as far as you can go to the base of the casing. See the pictures or video for a better visual.
Step 3: Sanding Off Excess
With the sanding drum, sand the casing wall that couldn't be trimmed with the tin snips. Go as far down until you reach the base of the casing.
NOTE: Try to keep the base as flat as possible, as this will ensure an even contact surface between the casing and the cufflink blank.
Step 4: Smooth Out Casing Base
Place a piece of 220 grit sanding paper on a flat surface and sand the base of the casing to ensure it's flat.
Step 5: Prep Cufflink Blank
Using the same technique as the previous step, roughen up the surface of the cufflink blank. This will help it make a better bond when the E6000 is applied.
Step 6: Assemble
Add a couple drops of E6000 to each surface, wait two minutes (per manufacturer instructions), and then put them together. It's best to let them dry overnight to ensure a strong bond.
Step 7: Polish
This step is optional, but it makes the final product look so much better!
I used a polishing wheel and compound that came with a Dremel brand kit found on clearance at Lowes.
Step 8: Final Product!
With these steps, you'll be prepared to make your own bullet cufflinks! They're perfect for Father's Day, Weddings, or gun enthusiasts, or if you prefer to skip the DIY part, I have this and other bullet items for sale in my Etsy shop!