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This is for anyone who has seen Xmen II and really wanted the cool Pyro lighter. But Zippo inc. refuse to produce replicas and won't let anyone else make them. But they can't stop you doing it yourself (as long as you don't sell them)

Step 1: Materials

I've seen people try to paint the design on but I use sheets of signmaiking vinyl. Normally you see this stuff in big rolls, but you can get it in A4 sheets if you look on eBay. For this you need 3 colours Black Red and White.
Also you will need a plain zippo lighter. 2nd hand zippos are cheap off ebay or a non zippo brand lighter will do.
you will also need : lighter fluid, scalpel)

Step 2: Cutting the Pieces

I used this general template, which should fit a standard Zippo. You can trace it or , as I did, print it on the back of your vinyl sheets. You need to cut two large strips of white, two zigzags of red to make teeth and the smaller strips of black for the edges and eyes/ gills. You can use scissors but a scalpel or craft knife is best.

The black template is a rough guide you may want to make it thicker if you are having trouble cutting it out.

The dotted line shows where the lighter opens.

Step 3: Preparing the Lighter

Make sure your lighter is clean before starting. Lighter fluid works fine to remove grease or sticky marks. Then with a pencil mark out where the stickers will start (to help get it centred)

Step 4: Applying Vinyl

Peel off the backing and apply carefully, starting with the white stickers.
Try to do it in one smooth motion, avoiding bubbles. Smooth over and press down with a cloth to ensure a good seal.
Apply the stickers as shown to build up the design.
When it's done the vinyl should be fairly permanent. As a display piece it will be fine, but if you carry it around in your pockets and use it it will deteriorate after a few months, mine lasted about 6.
<p>nice</p>
<p>FINALLY! I made it! </p><p>That Zippo stayed one year in my desk waiting to be so awesome :v</p>
<p>I made it a few years ago, the bad thing, the vynil get off to quick...so I use some fire to make it stronger (no it doesnt melt 'cause the metal get the heat and the glue just dry. awesome instructable :D</p>
weres the eyes and gills!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! <br>
could u tell me what colours you use please
really dude you cant read?
A trick people use to put graphics on dirtbike plastics is to first spray windex on the surface -- then you can move the vinyl around and remove bubbles and once the windex drys, the adhesive sticks.
I didn't know that, I'll probably use that sometime.
I recently used that technique when I was doing some graphics for my friends rally car. It works best on large stickers, but I don't think it would work for small things. Worth a try tho
can u email me the paper for the cut out and stuff they wount let me sine up beacuse i am in germany <br /> so yeah <br /> it is <a href="mailto:austinwimberly@yahoo.com" rel="nofollow">austinwimberly@yahoo.com</a>
&nbsp;k, I've sent it.
sweeeeet&nbsp; !!!!!!!!!!!!!!!!!<br /> <br /> would paint last longer then vinyl??? if so how much longer???<br />
Depends on the sort of paint. Enamel would be best. But it would slowly chip off and if you had keys or something in your pocket it would get scratched.<br /> <br /> Both would probably last equally as long. But they way in which they degrade over time would be different (paint would chip and scratch, vinyl would begin to peel at edges)<br /> <br /> Also I have no idea what the effect of repeatedly exposing the paint to heat would be.<br />
1 more thing.....after the paint/final has died and needs to be removed u can just redo thed desighn right<br />
&nbsp;To replace the vinyl is easy. Just peel it off and get rid of any sticky marks using lighter fluid (or similar). <br /> <br /> To redo a paint job you would have to sand back / chip off any remaining paint. Then cleaning with white spirit before re-painting.
k thanks<br />
would paint last longer? if so how much longer<br />
No I don't think it would last any longer. <br />
someone can put a link where i can buy the vinils? Thanks
uk - <a rel="nofollow" href="http://cgi.ebay.co.uk/A4-sheets-Self-Adhesive-signmaking-VINYL-Stickers-9year_W0QQitemZ160355853956QQcmdZViewItemQQptZUK_Crafts_StickersScraps_Decoupage_SM?hash=item2555f42684&amp;_trksid=p3286.c0.m14">http://cgi.ebay.co.uk/A4-sheets-Self-Adhesive-signmaking-VINYL-Stickers-9year_W0QQitemZ160355853956QQcmdZViewItemQQptZUK_Crafts_StickersScraps_Decoupage_SM?hash=item2555f42684&amp;_trksid=p3286.c0.m14</a><br/><br/>us - <a rel="nofollow" href="http://cgi.ebay.com/Vinyl-Adhesive-12-x-12-Cricut-Expressions-1-sheet_W0QQitemZ200377901790QQcmdZViewItemQQptZLH_DefaultDomain_0?hash=item2ea77422de&amp;_trksid=p4999.c0.m14">http://cgi.ebay.com/Vinyl-Adhesive-12-x-12-Cricut-Expressions-1-sheet_W0QQitemZ200377901790QQcmdZViewItemQQptZLH_DefaultDomain_0?hash=item2ea77422de&amp;_trksid=p4999.c0.m14</a><br/><br/>these are some ebay retailers who sell in small enough sizes. I used the uk seller, can't vouch for the other one.<br/>
where did u get the sharkface picture from
The picture in the intro? Is a picture of a replica. I found it on google images.
where are the eye and gill cutouts?
They are so small that I found it impossible to follow a guide. The gills and eyes are best done with scissors , just judge it by eye
There are no gill, eye, and nose cutouts in the picture. How do we make them?
nevermind i read the directions :)
Cut outs are too big by a fair margin. I used it on a genuine Zippo and it printed out too big by miles. So scale down a wee bit b4 cutting out. Although I could be missing something maybe?
I printed these straight off of publisher, it's entirely possible that somewhere along the line they have changed from their original scale.
Download the original file and rescale it in Irfanview to like 70% and it looks like the right size. Still a great instructable, can't wait to finish it! :D
Thats cool. I wish the pictures were better.
sorry bout that, i took these a while ago and they were done on a web cam.
Nice! How does the vinyl hold up in high temperatures?
if you put the vinyl in an open flame it will burn, but you can leave a zippo lit for ages and the vinyl won't , like melt off or anything. This stuff is meant for outdoor signs and is weatherproof.
Wow, it looks really good!
I've done this before on a cheap zippo copy with an iron on t-shirt transfer , just print what you want and iron it it on looks just as good
Any pure alcohol like Isopropyl will do just fine for cleaning this and the vinyl. Nice idea and well executed though you could make the thing as one piece and then put the slice for opening in with a scalpel...

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Bio: Studied Architecture at Brighton But now spend a lot of time building replica props or random gadgets.
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