Intro: How to Make a Ninja Star From a Sheet of Metal
In this Instructable, I am going to show you how to make a ninja throwing star out of an old computer case that you might have lying around.
Step 1: Things You Will Need
You will need the following items in order to make a throwing star:
A pair of scissors to cut out your stencil design,
A pencil to draw your design,
A piece of paper to be your star stencil,
A felt tipped marker to trace your stencil onto the metal,
A piece of sheet metal, I used an old computer case,
A dremel with a cutting wheel, or another tool to cut out the star,
A belt sander, or tool grinder to sharpen the edges of the star,
A piece of sand paper to buff the edges on the star,
A file to get a better edge on the star.
Step 2: Start Making Your Ninja Star Design
First, you have to take your paper and draw a design on it. You might need a ruler, compass, or protractor to help you out, but all I needed was a ruler. So basically all you have to do is draw a series of triangles that intersect each other and make as many points as you want. I decided to go with a four pointed star, but you could do as many as you wanted. Next one I make will probably be the same thing I have now, but doubled. Make sure that the points are as even as possible, because if they aren't, when you make the star, it will be uneven when you try and throw it, and who wants an inaccurate throwing star?
Next, you cut out the design with a pair of scissors, cut as close to the lines as you can. Now that you have your stencil, lets go to the next step!
Step 3: Tracing the Design Onto the Metal
Now take the design and hold it onto the sheet of metal, and trace along the edges. Trace along the edges carefully and make sure that you don't push against the paper too hard or the marker will make a weird line. You can trace it as many times as you want, or you can go ahead and cut one out and then make the metal one your new stencil.
Step 4: Cutting the Star Out!
Now take your cutting tool and do what that tool does naturally, cut stuff out! I suggest cutting it very carefully, because now is the time that when you mess up, you mess up really badly. For those of you who don't have a dremel to use, go buy one :) hahaa, well if you don't then you really should go get one, maybe even steal your friends, but if you don't have the money, or any friends who are cool and have one, then I suppose you could use a drill and a hack saw or something I don't know, you will figure it out :)
Step 5: Fine Tuning Your Throwing Star
Now that you have cut the star out, you get to sharpen the edges }:) muahahaha! Just be careful while sharpening it that you don't sharpen it to fast, or your whole project is kinda screwed up and you have a weird looking shape on one of the points. All you do is take the metal star, heres when you can trace the metal star and make more with it, and hold it by the edges and gently press it onto the belt sander, or grinder, at about a 45 degree angle, and repeat this for every edge. Next, take the sand paper and draw it across the edges so that they are sharper and neater. Then for a final edge take the file and gently run it across the edges as well, and use a sharpening stone to make it as sharp as you want.
Step 6: Asthetics, and Testing!!
Now you can decide to paint it or not. I was going to spray paint mine black, which would of been freaking awesome, but I didn't have any black paint......so sometime soon when I get the chance I am going to paint it. The only thing to think about if you are going to paint it black, is that the star will be harder to find if you throw it and don't know where it landed.
Next.....Go throw it at something!! A word of caution though...don't throw it near anyones car, or near other people. After all this is a weapon, and it can seriously injure someone if you miss ;) so with that in mind, practice and practice until you can hit things easily.
Some tips, when you are throwing it, they tend to fly like a Frisbee, and depending on how you throw it, you can achieve different flight patterns, also it may be tempting to throw at your dog or cat, just don't do it please? :) Oh and yea i have to mention all that stuff about you not holding my liable for you injuring someone, and whatever haha, just have fun and be careful!