Supplies You Need:
(optional: galvanized wire or a paperclip you don't mind ruining)
Tools You Need:
Files/Sandpaper (optional: rotary tool)
Step 1: Planning the Design
The rectangular shape was originally approximately what size I wanted the brooch. Obviously it got a bit bigger than I'd wanted, but still of a nice, wearable size.
I used a permanent marker to draw on the inside of my opened can/sheet of metal and got out the safety goggles and tin snips.
Step 2: Cutting Out and Cleaning Up
Be careful, metal can be quite sharp! Wearing leather gloves can help protect you from cuts and scrapes. Remove pieces as you go along, don't try to just cut the whole shape out. Remove the main shape from the larger piece first and then start on smaller curves.
I used straight tin snips which resulted in some over-cuts in my sharpest curve. Thankfully, they get removed in the clean up phase.
KEEP YOUR GOGGLES ON.
Cleaning things up is almost as dangerous to your peepers as cutting the shapes out-- and moreso if using a rotary tool or other power tool to help out.
Get rid of the ridges your tin snips may have left, clean up sharp corners, file and rasp and work until you have a nice, rounded surface.
Add some texture with steel wool or a very light sandpaper if you wish and head onto the next step.
Step 3: Adding Details
OR: Take your file and heavily, repeatedly score the surface of your wire to create the rachis.
From here, we add lines out from it so it looks more feather-like. Add as many as you like, varying the pressure on your file.
Step 4: Complete and Wear
If it has become a bit warped, use the hammer to pound it flat. You may also choose to bend some details up slightly, but remember that even filed metal can still catch things.
Use a magnet to attach it to your lapel, brooch on one side of the fabric, magnet on the other. Depending on the density of the fabric, you may need a relatively strong magnet. No more pin holes in clothing or worrying about it ripping if the brooch gets caught on something!
Remember to keep magnets away from pacemakers and many electronic devices.