Make Shingles and Siding Out of Aluminum Cans (Beer Can Roof)

Make Shingles and Siding Out of Aluminum Cans (Beer Can Roof)
I haven't tested this long term but it seems to work on my chicken coop. Here's the rundown:
Using scissors or tin snips cut the ends off an aluminum soda/beer can and cut down the middle of the can to make a flat rectangular piece of aluminum. Then you lay the flat piece into the forming die and press it by stomping on it or hitting it with a hammer. In this Instructable I'll show how to make the die and then lay out the shingles on a roof.

Making these can be tedious but the end result is gratifying because the old cans are fulfilling an immediate second life. A 24"x24" roof area will use from 36 to 50 cans (excluding drip edge and caps) depending on the vertical spacing and shingle style; that comes to 900-1250 cans per roof square (10'x10'.)
Start drinking now if you plan to try this.

I've recently posted how to build the whole coop at Diylife.com

Materials:
Loads of uncrushed aluminum cans
Piece of 1x6 hardwood board
Two 1-foot 5/16" metal square rods

Tools:
Staple gun
Circular Saw, or Router, or Saw with Dado Blade
Tin Snips or Scissors
Square
Chisel
Hammer
Drill and bits
Gloves

 
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Step 1Prep Cans

Prep Cans
Obtain your raw resources at a local party, drinking buddy, or community service highway clean-up. My neighbor is my steady supplier of uncrushed cans. I find beer cans are best because they don't have a sticky residue like soda cans.
This gets sharp, so wearing gloves is important. Use scissors or tin snips to cut the top off the can at the seam where the can bends. Cut down the center to the bottom and then cut off the bottom of the can. You should now have a rectangular piece of aluminum sheet metal. To ease the workload, precut these over time as you get the cans. One of the pics below shows the beginning of a can cutting machine; I hope it works because my hands are tired.
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187 comments
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Mar 18, 2009. 7:06 AMbrynda says:
does anybody know how to make a coke can baseball cap out of coke cans? i would like to make one for myself. i love coca cole memorabilia, and would love to know any other ideas.
Aug 9, 2011. 5:23 PMalberto200031 says:
Indeed, it can be made by recyling the coke can through heating process. also known as Electrolysis, in which the well heated coke can melt at above 194 to 212 degree temperature.(boiling point). then set up a customized moulder, engraved with any sign/logo to cast with. while the cans already melt into liquid form. run to cast. and then become solidify again as it feel the air. this process has been used to produce many valuable material. domestically and industrial. let me know if you will like to get more update and tutorial practice analysis regarding this electrolysis.chloir -alkali chemical process. I can be of good help to you. then email me at (alberto200031@yahoo.com) or forward your email/site link. so that I can link you up with my online tutorial coaching blog. Regard. Alberto
Nov 1, 2010. 1:30 AMOle bally says:
The tins are opened flat as per our shingle idea, then each one is cut to the same pattern as the panels at the original cap design. A small leather punch is used to perforate the edges of each side of the now 'sorta' triangular can pieces about 5mm apart. Using a 'crochet' stitch, the cap is sewn together with wool...I will try to get a picture to show the finished product!
Jun 23, 2010. 7:07 PMtulekah says:
dummy it with card stock untill you have the dims correct
Jul 28, 2009. 12:23 PMcatboo22 says:
me too i collect coke stuff , i have a red banana seat lowrider bike with a coke sticker on de side and 13 glass coke bottles
Jul 30, 2011. 6:50 PMkaren608 says:
I have an older screen door that is rusty and metal peeling up, and this made me realize that since it is on the north side of the house, I can redo it with opened up, flattened out aluminum cans, for SURE. Thanks for posting your roof, recycling at it's best.
Jun 5, 2010. 11:52 PMAudreyvgs says:
I did this a couple of years ago, the logos fade fast, but that look was the "shabby type look I was going for. I wrapped the edges first, used staples, will look into the Monel type, don't know what that is. It's too hard, tho with a manual can opener. You'd give yourself carpal tunnel by the 100th one. I want a machine to cut the top and bottom off, leaving me the clean middle. Anybody know of one of these? My roof is still great on my bird cage after all this time outside.
May 22, 2011. 10:58 AMrlm98253 says:
I use a band saw.
Dec 12, 2010. 9:44 AMart_mogul says:
I have worked with a man who has used flattened beer cans for roofing and siding on a couple of shed-like structures here in Huntsville Texas (70 mi north of Houston). The problem he ran into is that strong UV exposure breaks down the integrity of modern aluminum cans much more quickly than aluminum specifically manufactured for this application. Someone else has eluded to this as speculation in a comment below and I can confirm that this is true. That said even in South Texas the cans will comfortably hold up for 5 yrs or so. Wind can also be a problem in areas with strong UV exposure since the cans begin to flake apart when they break down. The older galvanized steel used in beer cans that are found in vintage beer can house construction hold up many magnitudes better. He has experimented with a number of materials, including plastics and the limiting factor is UV as opposed to other types of oxidation. This is a cool idea for small projects in less sunny places though. I have found that I can buy excess aluminum roofing scraps from a local scrap recycler which could be used as shingles. I hadn't thought of making a shaper. This is being discussed here http://www.phoenixcommotion.com/forum/viewtopic.php?f=9&t=5 if anyone would like to chime in.
May 14, 2011. 12:33 AMjofuji says:
I live in Australia where the sun would be a huge issue. Is there not a UV protective paint on the market that could protect the roof longer?
Apr 16, 2011. 4:00 PMsoulmisfit says:
Thanks for your instructable! I also have a chicken coop with a wood roof and it needs better protection from the rain and sun. I'm going to try this or make a living roof. Either way a layer of aluminum cans will help.
I was just looking at tin cans halves for roofing material as well.
Nov 27, 2010. 1:55 PMMuzhik says:
If you didn't bother to "mold" the cans, could you simply flattened the cans to use as siding for your house?
Mar 27, 2008. 9:47 AMrnipper28150 says:
This is a really good idea! I would be careful on those sunny days, though. That roof will be hot and the reflection off of it will be bright.
Oct 17, 2010. 3:00 PMmechanixman says:
but even if the roof did heat up, a solar water heater will produce sooo much more HOT water!
Oct 23, 2010. 6:04 PMrnipper28150 says:
I was commenting on the reflectivity. There was a problem with a metal-skinned structure in LA, the bright reflection was actually blinding drivers and causing accidents. I think it was the LA opera house.
May 21, 2009. 1:14 PMconsolidatedwm says:
I agree that the roof would be hot but, the bulk of the heat would be reflected away from the roof I would think. This is a cool idea, maybe we should do an entire Guiness roof.......
Jun 23, 2010. 7:12 PMtulekah says:
i'd sure love to help you gather material...but i'm on a diet
Nov 19, 2010. 12:16 AMkarrock says:
You could always kill off some cans of that Anheuser Busch Drinking Water... (and no I don't mean Bud Light)
http://www.anheuser-busch.com/press/2010/Jan/Anheuser-Busch-Delivers-Canned-Water-to-Assist-Perry-County.html
Oct 15, 2010. 6:40 PMcaarntedd says:
Excellent instructable and excellent discussion. I'm doing this.
Oct 8, 2010. 12:36 AMOle bally says:
This is an awesome idea well done on the instructable! I have had it in mind for a while myself but never gotten round to it! We have hundreds of tons of cans here in Zim that litter everywhere! I'm also making a bottle crusher that'll reduce the disposable beer bottles to river sand grain size for use in decorative cement work! These projects are great for income for handicapped folk and charitable institutions!
Aug 9, 2010. 2:35 AMWhamola says:
Very cool idea. Time consuming, but cool. But yes, if you were planning to use this for more of a permanent structure for living or storage, using tar paper between the cans (er... shingles) and the wood would be the "proper" way of doing it. Good idea. Thanks
Jun 23, 2010. 7:10 PMtulekah says:
how about skipping the internal ridges and just put a 90 along each edge? a simble bending brake job and faster.
Aug 18, 2009. 7:43 AMawupper says:
Won't the steel staples rust away quickly due to galvonic corrosion?
Jun 23, 2010. 7:05 PMtulekah says:
aluminum roofing nails. i suppose you could make your own custom nails by glueing a bunch of nails to a board and spikeing a sand bed. then pour the aluminum and when it cools you would have a fakir's door mat...untill you cut it up into square headed nails. cast with the topds and bottoms of the cans.
Feb 21, 2010. 3:54 PM67spyder says:
I hate to be a "negative nelly" but you said 900 cans to cover 100 square feet (10X10), Where I live (maybe not where you live) beer and pop cans have a 5cent deposit which means that 900 cans will give you $45 which will easily buy 3 bundles of shingles which will coincidentally cover 100 square feet with much less work.  Otherwise a great idea
May 16, 2010. 9:14 PMwrenawild says:
Anyone can get plenty of free, empty cans. You wouldn't have to spend a dime. If you can't figure out how to collect some for free, you probably shouldn't be building a roof.
Apr 8, 2010. 4:58 PMDIY-Guy says:
Hmm, my neighbors would object to me "making money" off the deposit refund, but would be proud to contribute to a dog house or a shed that "beer built!" Some states have draconian tax and identification requirements which deny some people the right of refund. Maybe the beer-u-crats on the state payroll think the homeless are getting rich from cleaning up trash? That was the idea after all, was it not? Reduce the litter by making it valuable?

One or two layers of non-degrading aluminum will withstand the UV for decade after decade. My asphalt and mineral surface shingles always need replacing before their projected lifespan is up. Metal is more permanent.

Besides, this is all about re-purposing and DIY.  :) 
Good method, good results, good for RobbToberfest!


Apr 10, 2010. 7:14 AM67spyder says:
Don't get me wrong this is a fantastic idea.  Also I have been thinking a lot about the refund issue.  Although it motivates the uninitiated to be environmental it does discourage re-use which is better than recycling.  In a state where there is no deposit there are usually easier facilities for recycling the aluminum based on weight which you can still do after you cut the top and bottom off (the heaviest parts) once you cut up a can it is no longer eligible for the refund.  Mabe the bounty should be placed on the can top?? (RobbToberfest, Sorry about hijacking your excellent instructable with a political discussion)
Apr 30, 2010. 9:08 AMward1969 says:
This is brilliant and it is a great discussion. I don't think total costs are reflected in the use of first run shingles versus reusing aluminum cans. There's also something really cool about sticking it to the system. Nice job.
Apr 8, 2010. 8:59 PMKarroo Oakey says:
Most well done! As an Al scrounger it is brilliant that you are able to make a use for the sides and the top and bottom for your forge. I have found the sides to be a waste of time for the forge and have wondered if there isn't something better to do with them.
Feb 1, 2010. 5:02 AMsimony says:
 I'm definitely going to do this!

except I'm going to have the graphics on the outside
Sep 15, 2009. 6:55 PMrojotwo says:
You should've seen the refugy areas around Saigon during the war. Thousands of homes(shacks) roofed and sided with beer and sody cans. They just made a flat shingles and banged them on with the pretty side out. Quite a refreshing way to get 'r done.
Jun 4, 2009. 2:19 PMakyramoto says:
looks like it was for a chicken coop maybe!! NICE, great idea. I would def like to give this a try. I think the result is great looking!!
Mar 25, 2008. 8:22 PMPkranger88 says:
Great job... 1 thing though. Aluminum cans are usually near pure aluminum rather than an alloy, meaning they will oxidize in the elements rather quickly. A quick shot of paint should help that, but other than that, the patience you have to do that is awesome. Keep it up.
Mar 28, 2008. 9:08 PMkscience says:
the cans are treated to endure the liquid contents, and not yield a drink any more toxic than the alcohol within. They are not anodized, but are very similar to the extremely more expensive rolls of flashing you can buy. Plus, they shield the henhouse from RF fields, an unintended benefit. Cool idea. I bet it outlives the chickens.
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Author:robbtoberfest
Stay-home Dad. I like solar energy, boating and sailing, making stuff, melting stuff, and raising chickens.