Introduction: How to Make a Metal Rose

First thing you want to do when making a metal rose is make sure you have everything you will need to complete the project.


The materials needed for this project are-

-Scrap or non-scrap metal
-a metal rod

Tools that will be used to make this project are-

-Angle Grinder with cutting and grinding wheels
-Pliers (needle-nose preferably)
-Bench Vice
-Arc Welder with welding rods
-Propane Torch with Propane
-Drill Press and drill bits
-A marking tool (sharpie, chalk, wax pencil...)
-A ruler
-Safety Gear

Optional tools
-Plasma cutter

Any one who is injured in the process of making this project is responsible for their own injury. We are in no way responsible for any injury that may occur while building this. Proceed at your own risk.

Step 1: Cutting Out the Circles

You will need to cut out three circles from your scrap metal.
First you need to mark the circles on to the scrap metal Using a stencil to trace your circles, either a paint can or a roll of tape or anything with a flat edge that is round. After you have your circles drawn, you then proceed to cut them out. Using either a plasma torch or an angle grinder, cut out the circles as round as you can. you will end up with three similar disks. Don't worry about cleaning up the edges that will come later.

Step 2: Measureing and Cutting the Petals


For this step you will need your ruler and angle grinder (or plasma torch).
First you must find five points on the perimeter of the disk that are evenly spaced. You can do this several ways. Either take measurements and mark your points, or you could draw a star with the points touching the edge of the disk until it looks right. Either way you choose to do it; you will end up with five marks on the edge of the disk. Now you will draw them all to the middle of the circle until they meet at one point. This means its time for cutting. When your cutting the petals into the disk be sure not to cut all the way down the line, there needs to be enough room for the hole that will be drilled though it.

Step 3: Clean Up the Edges


Now that we have the petals cut in, its time to clean up the edges of the disk and to finish shaping the petals. For this you will need your Angle Grinder with the Grinding and Cutting disk. Be sure that the cuts are straight and all the way though the Petals. Run the grinder over the surface of the Petal Disk repeatedly until it is smooth or shiny. Once the disk is smooth, round the sharp corners of the petals. This will make it safer and give it a more realistic petal look. Don't rush yourself on this step. Depending on how well you smooth the petals and round the corners will determine the look of the final product.

Step 4: Drilling and Welding


Now we will begin the process of attaching the petals to the stem. For this you will need a Drill Press and an Arc Welder. First make sure the place is marked where you need to drill the hole. When drilling the hole be sure to not use your hand to hold it. Use pliers or a vice or something. If it starts spinning on the drill bit it will slice your hand up. Also be sure to drill a small hole to start the process. Then work your way up in Drill Bit sizes until you have the size hole you want. Once all three holes are drilled, take it to the welder. You will weld them from the top of the petals so the next set of petals will sit on the previous weld. This is all the spacing that you will need for it to look good. Be sure to weld the petals so the cuts don't line up or else it wont look like a rose when its finished. A good rule of thumb is to rotate the next disk so the cuts are 1/3 of the way past the previous cut. Remember to check that each weld is a good one before continuing onto the next one.

Step 5: Heating and Shaping


Now its time for the Final Step. For this you will need a Propane Torch and Pliers. Heat the Petals so that they are red hot. be sure not to burn yourself on them, never reach over the top of them. they must be bent in a pattern or else they wont look right. One side of the petal should lay on the inside of another while the other half of the petal is covering the one next to it. Keep the top petals tight so you have enough room for the other petals can be folded up with enough room. it will take several heating's to bend all the petals. Once your done folding the petals up, get creative with them. Organic things are never symmetrical. After your happy with your new Rose clean out the flakes of metal from the inside and quench the metal by spraying it with the water hose. The rest is up to you. You can paint it, or leave it as is. You could even make a vine of them. Turn them into art. Like this Gate for instance.

Comments

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Downard Works (author)2011-12-23

Who Would like to see us build this War Hammer? If we get 20 comments saying yes then we will build it. I would also like to apologies for not having the youtube video up yet. The hard drive I had the data stored on crashed and the data was lost, So we will have to film it again. I am sorry for the delay.

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Yes!!

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bransweerertjie (author)2011-11-10

I love it. And then I made it. It is one of the most awesome instructables.

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npa4863 (author)2011-10-09

my rose (the one on the desk) and my friends rose he made...
i like to use thinner metal and ive started to thread the rod instead of weld it as for my my welds suck (i was in the shaping proses and the weld failed i was pissed thru the thing across the shop), i cover the nut up with a coned piece of metal... i kinda wanna put one in a sand blaster so i can get a bead blast Finnish then clear coat it so it shines and docent rust...

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MikeW375 (author)2017-05-09

Added a stand and leaves

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D_heet made it! (author)2017-02-11

Amazing post! Thanks!!

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logant3030 (author)2016-07-12

Wow this is awesome!

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rashcroft (author)2015-12-03

I'm going to do this

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BrentDevcich made it! (author)2015-10-14

Awesome, very clear instructions, was relatively easy and I had a blast making it.
I used thinner material so I had to use a tig welder instead of rods, but other than that everything was the same as above.

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Harry8201 (author)2015-09-16

I'm trying to make this for a gcse technology project

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alexandtheshield (author)2015-02-08

How big approximately are the petal sections? I can't seem to get the correct size

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zde jong made it! (author)2015-01-25

easy way to make a beautiful flower

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andrewdwaring (author)2015-01-08

Here we go, not complete as i need to bash it a bit :-)

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bigmonty (author)2014-08-21

made mine in class got a lil more detailed with the stem and thorns. real easy. yet great product. Thank you for the instuctions.

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valveman (author)2013-03-24

What paint did you use to get the natural red colour?

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Downard Works (author)valveman2013-03-25

We use reds, maroons, and browns. we put a base coating of red spray paint, We then used a painting technique called Dry Brushing to add the finer details in the other colors. This is achieved by taking your paint brush and dipping it in the paint, Then have a paper towel or cloth ready. You then paint on the paper towel or cloth until very little paint is coming off. After that you use the nearly dry brush to paint with the remaining paint using light stokes of the hand. A few brush strokes is all it takes. Since most of the paint is off the brush already it will only paint the higher ridges on the in-prefect metal surface, and not allow the paint to soak into the lower valleys of the metal.

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ryco1995 (author)2012-10-14

Can you make a video of this?

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heartart (author)2012-01-19

Would you consider making a few and selling them? I make a LOT of things, but don't work with big metal or welding etc. I LOVE rose anything...
post how much they would be if you sell a few.
Thanks. Q www.wingedheartart.com

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Downard Works (author)heartart2012-01-27

it all depends on the number of roses, if they are painted or not, the size of the roses. There are many factors that will change the price. so what exactly are you looking for?

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Mtmtx (author)2012-01-04

How thick of metal did you use?

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Downard Works (author)Mtmtx2012-01-05

We have been using 16th gauge steel.

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LawnBoy1991 (author)2011-11-16

Could I possibly replace the drill press with an oxy-acetylene torch? It won't be a nice cut but I'm pretty steady with a torch.

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if you could keep the hole clean enough for you to weld to the metal rod. I don't see why not, We will never know until you try. keep me posted and please post pictures of your process.
`

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spiritwalker6153 (author)2011-10-08

What size circles are you cutting or does it really matter at all?

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However the size of the disks we made have a diameter of 3 3/4 inches.

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the size of the circle doesnt really matter its the space between the cuts into the disk that matter. it needs to be evenly spaced

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spiritwalker6153 (author)2011-10-08

This is a really cool project for someone who as some extra time. Maybe I will make one for my wife as it will be the only rose she will not have to smell.

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jongscx (author)2011-10-07

Oooh, I need to code this into the plasma table to make the pretty shapes...

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Downard Works (author)jongscx2011-10-08

But we have thought about how much cool stuff we could do with a Plasma Table.

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Downard Works (author)jongscx2011-10-07

We do all our stuff by hand.

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Downard Works (author)2011-10-07

So we just finished filming the process and now we are in the editing stage. we are going to make it as clean as we can for you guys.

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etkach (author)2011-10-07

So awesome. Makes me want to go make one right now. Great job and thanks for the tutorial [:

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Downard Works (author)2011-10-07

So what would you like to see next and Greased Lightning, or The Enforcer?

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Treknology (author)2011-10-06

What do you mean, "Turn them into Art"? They are already Art !!!

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Downard Works (author)Treknology2011-10-07

Lol. Thank you.

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bg_askins (author)2011-10-06

i like to bend the edges of the petals back while its red hot

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Downard Works (author)bg_askins2011-10-07

Great Rose.

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dragonflygirl (author)2011-10-07

This is freakin' awesome!

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wirechief (author)2011-09-29

That is slicker than snot! Great tutorial.

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Downard Works (author)2011-09-29

thank you everyone for all the great comments. i will have a video up with in the next couple days. ill post a link when its up.

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mikeasaurus (author)2011-09-28

They look great on the gate!

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Thanks. I was thinking of doing a youtube video on it. what do you think?

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that would be awesome!

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DaddyQ (author)Downard Works2011-09-29

Excellent idea. I'd watch it for sure.

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bransweerertjie (author)2011-09-29

Really really AWESOME

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DaddyQ (author)2011-09-29

Really nice work, well done. Very inspirational. I was on a metalsmithing course 2 or 3 weeks back and, hands now recovered, this makes me want to experiment again with what I learned. :)

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luckyjamie (author)2011-09-29

Wow, they do look great!