"Starfish" Nail Letter Opener

That's Clever! : Episode HCLVR-141 -- More Projects »
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Project by Kymberlee Maxine O’Brien from Cambridge, Mass.
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Kymberlee Maxine O'Brien's mother conducts horse therapy programs, thus horses have always been part of her surroundings. She used to bend the long horseshoe nails into interesting forms. Later, she discovered blacksmithing, taking classes in the art form. But she found that most ironwork was very large scale, and she wanted to do something smaller. She remembered the horseshoe nails, and started creating jewelry and other items out of them. She demonstrates a handcrafted letter opener, made with iron horse shoe nails and melted brass.

Materials:

5 medium size horseshoe nails
1 very large horseshoe nail
brass and copper flux coated rods
torch, oxy propane set-up
leather welding gloves*
safety glasses
jewelry grinder and wheels: wire, steel, buffing wheels, diamond grit wheels
metal polishes
metal lacquer
vice
anvil
hammer
pliers
firebricks
bucket of water
cloth
*Wear leather-welding gloves for protection when operating the oxy propane torch.

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Figure A
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Figure B
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Figure C
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Figure D
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Figure E
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Figure F
Steps:


1) Twist five small nails into starfish shapes by placing each one into a vice and bending with pliers (figure A). Place each nail into a small anvil and hammer the shapes flat (figure B).


2) Align the five shaped nails on top of a large nail on a flat surface (firebricks) (figure C).


3) Light the oxy propane torch. Heat the iron to "red hot" with the fire and flux coated rod. Melt the brass and copper rod onto the iron while sealing the pieces together. Melted brass is also used for decorating the iron surface (figure D). Allow to cool or immerse in a bucket of water.


4) Remove fire scale with a hand-held jewelry saw with a steel wire wheel attached (figure E).


5) "Sculpt" and "facet" the surface of the iron (figure F) with the diamond grit wheel. Sharpen the tip of the large nail with the wheel to create a pointed edge for opening mail.


6) Use the hand brush, remove any remaining fire scrape or dust with the polish wheel and white diamond polish. Polish with a cloth.


7) Finish with metal shiny lacquer and let dry.


Website: www.kymberleemaxine.com

Also in this Episode
That's Clever! : Episode HCLVR-141
•Papier-Mache Television
•"Starfish" Nail Letter Opener
•"Pumpkin Dude" Doll
•Ceramic Keepsake Box