Instructables Robot Burger - RoboBurger

Step 2 Follow the curves...

Print out a picture of the shape you want your burger. Size it to correspond to how big your buns are. The burger will shrink when cooked so make it a bit bigger to fit when cooked. A normal sized patty is about 4 1/2 inches in diameter and should weigh about 1/4 pound. Please convert to metric measurements if so inclined.

With the bent edges on the outside, gently coax the strip and bend it to fit around the shape on your paper pattern. Use needlenose pliers to make the sharp bends or creases. You can mark the points where it needs to bend and do if freehand away from the picture. Use a hammer to pound the aluminum over a dowel to get a smooth curve. Use your needlenose pliers to crimp any kinks that develop on the edges. Overlap the end enough to place a rivet there to hold it together. Drill the pilot hole for the rivet and rivet together. If you don't have a hand riveter, just tuck one end under the folded edges of the other and crimp. It will be enough to hold it together but may spring apart when you fill the form.

Wash and scrub thoroughly before use to remove any non-edible foreign matter and ink.