Constructing a genuine European 4 in 1 chainmaille weave using only pop tabs.
Turns out this is very easy and makes a really great looking piece of maille, and as an added bonus you don't have to worry about having a quarter mile of wire on hand to attach them together.
Step 1: Assemble your supplies
OK, you are going to need lots and lots of pop tabs. Don't give yourself renal failure trying to drink them all yourself. Spread it out or enlist the help of your family, friends, workmates, or maybe even the local recycling center. Here is what you will need:
Non-mangled pop tabs (however many you need, 1000 is a good start)
Step 2: Prepare the tabs
You will need to prepare the tabs for the weaving. Bend the collar down from the "top" side of the tab using the tumbler side of the key. Then use the back of the key to continue bending it down against the side of the tab. Lay the tab face down and push the cupped part down flat.
Step 3: Cut
Now that all your tabs are flat and consistent, you need to cut and crimp them.
Cut them in the very middle of the pull part of the tab, or for a stronger connection, on the rivet side, either way just be consistent.
Step 4: Bend
The tabs will need to be bent slightly so they will lay together properly. This is where the staple remover comes it. Turns out it gives it just the right amount of bend. Put the tab in cut side first and close the tool down so that one side holds the cuts and the "bridge" is over the metal edge on the other side. Press with your finger and, bam! you're done.
Step 5: Repeat
Keep making the links, do them all at once, do them in batches. Either way, its pretty easy to make them.
One note: If you are using cutters, you can bend the tabs first, if you are using scissors you have to cut them first.