Introduction: Handmade Bullet Pendants
Hello everyone, in this Instructables I'm going to share with you the process I use to make these bullet pendants.
You will need some bullet cases, the calibre will determine the final size of your pendant. In this instructable I will be using a .223, the large crosses are made with 375 H&H MAG but these are very difficult to cut and shape as they are very thick so I would suggest starting with a .223
Also you'll need a dremel with abrasive cutting disks, a small drill bit, a hammer, some sanding paper and polishing compound.
Step 1: Getting Started
WARNING!!! BEFORE STARTING MAKE SURE THAT YOU ARE USING A SPENT CASE AND THAT THE PRIMER IS NOT LIVE!
Grab your bullet case and mark where you will be cutting it, as this will be a cross I will be dividing it equally in four.
I use a utility knife to scratch a mark down the side, as the bullet is round it will be easy to mark a perfectly straight line.
Using a Dremel with abrasive cutting disks start cutting down the lines that you just marked until you reach the indent on the top of the bullet.
Be careful as the bullet heats up quickly while cutting. ( I like to hold the bullet in a wet rag when cutting, this keeps it cool and catches all the dust. )
Step 2: Open Wide
After your bullet is cut you need to flatten it out.
To do this I use a rod with a rounded tip, hammer it into the bullet to open up the 4 slots you just cut.
I then use a hammer with a wooden block to flatten out the legs completely.
If you are struggling with this step it can help to heat up the bullet to a dull red with a butane torch and then quench it in water. This will anneal the brass making it much easier to bend.
After annealing you will have to work the cross with a hammer to harden it again otherwise it will be very flimsy.
Step 3: A Little Off the Top
Now that we've got our basic cross shape we will need to trim the excess so that we can get a nice cross, how much is up to you and how you would like the final product to look.
You can use a pair of side cutters to cut the sides as these will be thin and easy to cut and gives you more control.
Don't worry if it's not perfect you can always trim it back some more or even change up the design a bit.
Step 4: Finishing Up
Before we sand and polish the bullet I like to use the abrasive disk to cut some additional designs into the bullet to make it a bit more unique.
Now you can use some sanding paper to remove the imperfections and burrs.
I start with a rubber abrasive wheel in my Dremel, then 400 grit sanding paper and move up to 2000 grit.
After sanding you can use some polishing compound with either a felt buffing pad or a cloth to get a nice shine.
All that's left is to drill a small hole for a split ring so that you can attach it to a necklace/keychain etc.
Happy making and don't forget to share your own creations in the comments.
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