This is a step by step guide, paired with a video on how to make a simple aluminium spatula.
This would make a great first metalwork project for kids at home or students in a technology classroom.
Step 1: Step 1
Design your spatula
Think about the shape and what material(s) you want to use for your handle. Do you want twists, a wooden/alu handle or an alu/acrylic handle?
Step 2: Step 2
Cut out your aluminium for the flipper part of the spatula.
Use the metal shear. Check the material is lined up before cutting.
Step 3: Step 3
If you need to cut your flipper piece, use a junior hacksaw to cut your aluminium.
Use a file to smooth and round the edges of your shape.
There should be no sharp edges.
Step 4: Step 4
Cut your handle using a hacksaw or the metal shear.
Step 5: Step 5
Measure your flipper and find the middle so you can line up the handle.
Line up and mark out your holes on the handle metal. Use a punch to create a guide for your drill bit so it doesn’t drift.
Step 6: Step 6
Drill 5mm holes through the handle and flipper. Use a file to take all the rough edges.
Step 7: Step 7
If you want to stamp your name or a slogan on your handle do it now.
Use the letter punches with a hammer. Make sure you have a metal block under your handle. Do each letter with one hard strike, NOT repeated strikes...
Step 8: Step 8
If you want a twist on your handle put the handle material in a metal vice.
Attach a vice grip to the top making sure its tight and rotate it until you have your desired twists.
Step 9: Step 9
If you want a curved end put your metal handle in the vice and bend down. Bend the rest round by tapping it round with a hammer.
Step 10: Step 10
Next we need to bend the flipper on the metal bending machine.
If you want holes or grooves in your flipper now is the time to do it. They will need to be filed after drilling.
Step 11: Step 11
Next we need to rivet the handle to the flipper. Make sure your rivets line up with holes and rivet together. Squeeze from the end of the handle for more leverage.
Step 12: Step 12
File down the back of the rivets where they come through, and any other sections that need smoothing.
Step 13: Step 13
Clean off using some soapy water.
Step 14: Step 14
TEST IT OUT