Making a Brass Pocket Flask





Introduction: Making a Brass Pocket Flask

About: Working as a wood/metal shop teacher for kids 9-12 years old. Restoring a old house and a Saab 95 V4 1975. Currently bad at making new ibles but will hopefully find time soon...

I'am educating myself to be a proper wood chop teacher, have been working as it for four years and mostly need the degree to get a steady job and decent pay.

One of the many tasks we got was to make "a box with a lid" and i interpeted that as a pocket flask since i prefer to make thing that could be useful.

You need brass, lead-free tin, a 3/8" lid, a 3/8" sleeve, some paper, sheet metal cutter and soldering torch. The lid are the same kind thats used on radiators and plumming, easy to find and usually cheap.

Step 1: The Template

Start by making a template, think about how you want it to look. A made mine with a bit of airfoil shape, it hides nicely in the pocket.

Step 2: Cut the Metal

Use glue if you want to prevent the paper from moving. Make the top and bottom a bit larger, it should be ground down later. The top and bottom are the same shape so you only need to make one.

Polish the edges of the straight piece. In the next step it should be solderd.

Step 3: Soldering

Start by soldering the straight piece and the sleeve with silver solder.
If you use tin solder here it will part when you attaches the top and bottom.

When the soldering is ready you have to clean it. I used a light acid bath to cleance the metal.

Step 4: Tinning

Now we apply lead-free tin on the inside and if you want on the outside. The brass must be absolutely clean, use steel wool to clean if necessary.

Step 5: Assembly

When its tinned its time to assembly the flask. Solder the top and bottom pieces with tin solder.

Cut of the unnecessary brass with a metal scissor. Ground the edges to the right shape.

If you tin the outside you might get a nice effect by not soldering the ground areas.

Step 6: Polish

Polish the flask with steel wool until it's good enough to give to your father. Make sure to clean it properly inside.

Use it with care, alcohol is not healthy, it's illegal to carry it in some places and times.



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    21 Discussions

    Sorry for late reply but maybe something like this?

    Do you remember specifics of any of the materials you used, like thickness of the sheet metal?

    Are real hip flasks you can buy made this way? Soldered or welded?

    From what i heard its because tin is one of the few non toxic metal, most other are a bit unhealthy.

    maybe that is why the manufactured ones I have seen are made of Stainless. Nice project though, as much as I like scotch I would have to carry the bottle with me to keep the flask full. I have lots of silver solder though so maybe I will build a fifth flask ;) Thanks!

    Thanks to all of you!

    The degree includes both metal, wood and leather work byt is usually refered to as just Trä-slöjd / wood chop in Sweden.
    Slojd is a bit hard to translate but the origin of the word is "sluug" to be handy and cunning.

    It's a bit controversial to make pocket flask with 15-16 year old pupils but they usually love it and promise to wait until they are 18 to use it for strong alcohol...

    If i get some spare time i'll upload some more works. This 'ible i did mostly to not have to do a powerpoint about the flask. ;-)

    1 reply

    I was going to make a joke about High School kids making whiskey flask LOL. Might want to call it a water bottle (wink wink)

     Does this require pure silver solder or is a mix of tin, silver, and copper okay?

    1 reply

    A mix should be ok as long as it doesent contain any harmful metals as lead.

    nice flask! im gonna try and make one
    good job man!!!!!

    how do you tin the inside and outside of the flask, do you just melt tin onto it or what?  THanks for your reply and time.

    2 replies


    I used tin paste. A quick googling gave something like this:

    You just apply it to the metal and heat it up. It you want a shiny surface you wipe it with a soft cloth while it's still soft.

    I like this, you did a very good job. I'm going to have to try this sometime, and if I do good, give some as gifts.
    As for the acid etches, yeah, you should do that. Its in the flux plumbers and jewelers use to prep metals for brazing.

    Favorited and 5 stars

    excellent work. an easy way to clean the slag and fire scale from inside the flask is to fill it part way with water and a hand full of sand. put it in your pocket while you walk around during the day. i have done this a few times n the past with good results. be sure to rinse the out thoroughly. again, excellent work. very well explained, and lots of clear photographs

    This is great, and like lemonie said, you should seriously consider becoming a metal shop teacher instead.