Have you ever wanted to add a touch of handmade elegance to your desk or surprise a friend with a unique and practical gift? Forging your own custom metal letter opener is a rewarding project that combines artistry and functionality. It’s also a great way to dive into the world of blacksmithing, even as a beginner. In this guide, we’ll walk you through the steps to create your own beautiful and durable letter opener from a simple piece of rebar.
Gathering Your Blacksmithing Tools
Before we light up the forge, let’s gather the tools you’ll need for this project. Don’t be intimidated by the list – many of these are basic blacksmithing tools, and you can find them at most hardware stores or online blacksmithing supply shops.
Here’s what you’ll need:
- Tongs: For safely holding and manipulating the hot metal.
- Rebar: A readily available and affordable steel alloy.
- Anvil: Your trusty work surface for shaping the metal.
- Forge: To heat the rebar to a malleable temperature.
- Flat-faced hammer: For general shaping and flattening.
- Ball-peen hammer: For rounding edges and creating textures.
- Vise: To hold the metal securely during certain steps.
- Metal wire brush: To remove scale and impurities from the hot metal.
- Safety Gear: Always wear safety glasses and heat-resistant gloves when blacksmithing.
Step 1: From Rebar to Tapered Form
1. Heat and Taper One Edge:
- Begin by heating one end of the rebar in your forge until it reaches a bright orange color. This indicates that the steel is malleable and ready for shaping.
- Place the heated end of the rebar at an angle on the edge of your anvil and, using your hammer, strike angled blows to create a taper at least one inch long.
- Regularly check the tip of the taper for a shallow space. If you see a space, drive your piece onto the anvil face to flatten it and continue tapering.
2. Shape the Other End:
- Heat the opposite end of the rebar in the forge.
- This time, we’ll start by creating a square taper. Use your hammer to flatten four sides of the heated end.
- Once you have four flat sides, place the tapered end back into the forge.
- While it’s heating, secure the squared end in a vise. Using a twisting wrench positioned at the base of the flattened section, twist the handle one full turn to add a decorative element to your handle.
3. Round the Taper:
- Heat the tapered end of the rebar once again.
- Place the piece on its edge and strike it with your hammer to transform the square taper into an octagon.
- Continue hammering until all edges are smooth and rounded.
4. Refine the Handle End:
- Flip the piece over and heat the squared end in the forge.
- Once hot, taper this end for approximately 3 ⅓ inches, aiming for a pointed tip of about 1/16 of an inch.
Step 2: Flattening the Taper for Strength and Elegance
Now that you’ve created the basic shape of your letter opener, it’s time to refine the blade.
- Consistent Hammering: Using your flat-faced hammer, work both sides of the blade with consistent, overlapping blows. Focus on achieving a flat surface while maintaining a consistent thickness.
- Mind the Thickness: It’s important to avoid making the blade too thin. Aim for a thickness of at least 3/16 of an inch. Having a sample letter opener on hand can be helpful for comparison.
- Smooth Out Hammer Marks: Once you’re satisfied with the flatness, use a flat-faced hammer to carefully smooth out any noticeable hammer marks, creating a more refined finish.
Step 3: A Sharp Bevel for a Functional Edge
The next step is to create the sharp edge of your letter opener.
- Angled Beveling: Hold the piece at a consistent angle close to the anvil’s edge. Strike with angled blows, maintaining consistency and overlap.
- Working Both Sides: To ensure an even bevel, work on both sides of the blade by repositioning it at each edge of the anvil. It’s helpful to stand behind the anvil to have a better view and control.
- Maintaining the Curve: Remember that the blade is curved, so you’ll need to rotate it continuously to keep the edge close to the anvil’s edge.
- Bevel Width: Aim for a bevel width of at least ¼ of an inch.
- Rounding the Back: Once the bevel is formed, use a ball-peen hammer to work the backside of the blade over the horn of the anvil. This helps to refine the curve and create a more comfortable grip.
Step 4: Shaping a Comfortable Handle
- Heating the Handle: Place the handle section of your letter opener back into the forge and heat it until it reaches a malleable temperature.
- Creating the Curve: Using your tongs, firmly grasp the handle and place it into the pritchel hole of your anvil (the small round hole). Carefully pull the handle in the direction of the blade edge in small increments to create a comfortable curve.
Step 5: Finishing Touches for a Polished Look
- Removing Impurities: Reheat the entire letter opener in the forge. While it’s hot, use a metal wire brush to thoroughly remove any slag or scale that has formed on the surface during the forging process.
- Protecting the Finish: Immediately after removing the slag, dip the hot letter opener into a bucket of oil. This step helps to protect the metal and prevent rust. Repeat the dipping process several times to ensure complete coverage.
- Enhancing the Color (Optional): If you desire a darker, more aged look, you can hold the oiled letter opener near the forge. The heat will cause the oil to burn off slowly, resulting in a matte black finish.
Show Off Your Craftsmanship!
Congratulations! You’ve just forged your very own custom metal letter opener. This unique piece is not only a testament to your newfound blacksmithing skills but also a beautiful and functional addition to your desk or a thoughtful handmade gift for someone special.
Learn More and Explore Your Creativity
Forging a letter opener is just the beginning of your blacksmithing journey. There’s a world of creative possibilities waiting to be explored! If you’re eager to further develop your skills and tackle new projects, be sure to visit Robert Kline Art for more inspiring blacksmithing guides and resources.