The Blister

Materials/tools 

- 200 x 200 annealed aluminium sheet

- Plastic mallet

- Sand bag

- Mineral Turpentine

- Cloth

- CNC blister template

- Tin snips

- Screws and nuts

- Small wooden mallet

- Timber corker

Procedure

Step 1 - Choose template of what shape your blister will be the larger and more broader the blister the easier it will be. The templates cut using a CNC. template photo below.

Step 2 - Sandwich the aluminium sheet between the two templates and drill through the holes in the template to create holes in the aluminium. Insert screws and screw nuts on ensuring they are tightly fixed.

Step 3 - Using the plastic mallet photo below strike the aluminium through the template. ensure to start you use the flatter and more round face of the mallet to ensure you keep a smooth face on the blister. Tip: place a sand bag under the template when striking with mallet too ensure the base of the blister stays rounded.

Step 4 - Using the more pointed side of the mallet strike the edges of the blister. This will give the blister more depth closer to the edges. While doing the use the small wooden mallets flat edge to smooth out any large dents in order to keep the smoothness.

Step 5 - Using a piece of timber disc sand it to create a pointed edge, this will be used as a corker. What this does it help in getting depth and sharpness to the edges and pointed end of the blister. Using the corker place it on the edge and strike it with the mallet. Work your way around the blister and pointed end until you have your desired edge sharpness. Note: the corker will go blunt and will need to be re sanded to hold the original shape.

Step 6 - Using tin snips or the sheet metal cutter cut evenly around the blister following the outline.

Step 7 - Now complete polish the aluminium with some mineral turpentine and a cloth. This removes and blemishes, dirt and oxides in the metal giving it a nice shine.

Final Product

The Tray

Materials/tools 

- 200 x 200 annealed aluminium sheet

- Plastic mallet

- Mineral Turpentine

- Cloth

- Timber tin template

- Tin snips

- Vice grip

- Sanding block

- Marker

- Ruler

- Radius stencil

Procedure

Step 1 - Using a marker and the radius stencil mark on the timber template the desired curvature of your tin. once template is marked use the disc sander to create curves on the edge of the timber.

Step 2 - Cut the aluminium to the same shape as the timber template but add an extra 5mm approx (depending on how deep you want your tin) of aluminium around the template. Then cut aluminium neatly with the tin snips. 

Step 3 - Sandwich the aluminium sheet and the timber templates to in a vice. what you should see is the two timber templates hugging the aluminium with the over cut of the aluminium (5mm) sticking out all the way around.

Step 4 - With the rounded plastic mallet start to strike the aluminium overhang to form a 90 degree angle around the timber template. work your way around the tin until you get to a corner. Once you get to a corner strike it to the template but be cautious not to create a fold in the aluminium. The aluminium will stretch and any excess metal that is not needed cut away with the tin snips. Repeat above until all 4 corners are complete.

Step 5 - Repeat steps 1-4 with second sheet of aluminium to form mirrored piece

Step 6 - Now complete polish the aluminium with some mineral turpentine and a cloth. This removes and blemishes, dirt and oxides in the metal giving it a nice shine.

Final Product

The Torus

The Bowl

The Bowl

 Materials/tools 

- 200 x 200 annealed aluminium sheet

- Plastic mallet

- Sand bag

- English roller

- Methylated spirits

- Cloth

- Marker

- Radius template

- Tin snips

Procedure

Step 1 - Using the radius template and marker, draw concentric circles on the aluminium sheet.

Step 2 - Using the tin snips cut tightly around the circumference of the largest circle

Step 3 - Using the plastic mallet and sand bag strike along the marked line of circle using the pinted side of the mallet. 

Step 4 - Using the plastic mallet again strike the same line all the way around but this time with the broader side of the mallet.

Step 5 - Repeat steps 3 and 4 for the inner circles 

Your piece of aluminimum should now be resemblant of a bowl with vaious highs and lows in the metal.

Step 6 - To smooth out these highs the english roller will be used. With the aluminium bowl push and pull it through the roller making sure not to make sharp movements. your movements should resemble a lawn mowers systematic direction in order to cover all areas of the bowl.

Step 7 - Repeat step 6 until you have your desired shape and gradient of the bowl. In order to get a polished finished on the bowl clean the bowl with a cloth and methylated spirits as often as possible when using the english roller.

Final Product