Picture of Pyro Lighter design, the Zippo from Xmen II
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)
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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

Picture of 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

Picture of 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

Picture of 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.
where are the eye and gill cutouts?
madmanmoe64 (author)  akirakun99936 years ago
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
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?
madmanmoe64 (author)  Sicklycrypsis6 years ago
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