I made it at TechShop.

www.techshop.ws

Step 1: Start Off With a Piece of Steel

Start off with some mild steel.
This 6" piece of 1.25" flat bar stock was provided by Techshop as part of the Basic Metal Shop SBU class.

I used the Horizontal Bandsaw to cut a down a 3ft piece to the usable 6in.

Step 2: Draw Your Pattern

use a sharpie, nail, scratch, etc to put an outline of the shape your going for.

The main idea is drill ~.5in hole and use vertical bandsaw to cut off the pieces you don't need.

Step 3: Drill and Cut

Use a Center punch to mark the center of hole you want to drill.

Next use smaller drill bit for a pilot hole. Then drill out using a .5 inch drill bit. Be sure to secure your work to a table or using a drill press will make the job pretty easy.

Next, Using a vertical bandsaw cut off the unwanted pieces. It helps to start with the short cuts so you don't have to back out of a long cut.

Step 4: Start to Shape It

Take your work over to the grinder and disk sander take off the edges.

You could stop here and have a usable bottle opener for the tool box or garage....

I on the other hand wanted to shape it a little more.

Read on to see more.

Step 5: Finishing Touches

I went a step further and shaped the bottle opener a little more with the grinder and sander.

After that I used a rotary tool (Dremel) with some smaller sanding attachments to shape the hard to reach places.

I also decided to put a little shine on it, using a buffing pad attachment and some polishing compound.

I know I could have done it differently by using a series of different grit sand paper progressively getting finer and I could have have gotten a nice mirror finish on it.