BY: Lauren DiSanza
SKILL LEVEL: 4 (1 being the easiest, 5 being most difficult)
TIME TO COMPLETE: 2 hours (does not include drying time)
• Always, wear safety goggles when using glass-crafting tools. Everyday eyeglasses have only impact resistant lenses.
• To ensure top performance keep your bottle cutter blade oiled.
• 1 Generation Green™(g2) Bottle Cutter
• 2 Discarded Bottles with similar diameters
• 7/32” Copper Foil
• Studio Pro™ Lead Free Solder
• Studio Pro™ Soldering Iron
• Fid or Pencil
• Flux and Flux Brush
• Sharpie® Marker
• Black Patina
• Copper tube hinge assembly ( outer tube cut into 3 - ¼” portions and inner tube cut to 1- ¾” section)
• Long Tweezers
Read and carefully following the instructions contained within the Generation Green (g2)™ bottle cutter manual.
1. Cover the work area with craft or newspaper. 2. For our trinket box we used two similarly shaped 750 mL clear wine bottles. You can choose to use any jar you desire as long as they have the same diameter. Measure up from the bottom of one bottle 1 1/2” and mark with a Sharpie®. Repeat with the second bottle measuring up 1/2”. CREATIVE TIP: Use leftover bottoms from old projects or use the top portions of these bottles to create something useful too like a luminary or candle shelter!
3. Using the bottle cutter, follow the instructions for scoring and separating glass jars. Separate jar where indicated.
4. Smooth the rough edges as instructed in the bottle cutter manual.
5. Clean your bottle inside and out with a window cleaner or for a more natural cleaner use a mixture of 1 cup of water to 2 tablespoons of vinegar. Dry glass surface.
6. Foil the edges of each piece first. Start with 7/32”, 1.5 mL thick copper foil. Peel back 2” - 3” of backing from the foil, hold glass with the edge toward you, and apply foil to the edge of the glass so that it extends evenly over both sides of the glass. CREATIVE TIP: Foiling a circular object can be a bit tricky, use a scissors to make small slits in the foil to help get a smooth foiled curve.
7. Fold or crimp foil over edges making sure to fold edges are neat and flat. Burnish foil using fid or a wooden craft stick. Press foil flat against glass on the outside edge first, then both sides of the glass. Don’t scrub as you may rip the foil.
8. Randomly apply strips of foil on the exterior of each piece, but try not to overlap the pieces more than once. Burnish the foil so that is stays in place.
9. Tin each piece, to do so, apply flux to the foiled portions and apply a small amount of solder over the foil. 10. When both the lid and the base of the box has tinned, and cooled, lay the smaller piece (the box lid), flat on the work surface with the opening facing down.
11. Next, to create the barrel hinge, use a hand saw or the Precision 2000 and cut three 1/4” lengths from the cooper tubing of the hinge assembly. Rub the cut edge against a piece of sandpaper to remove rough edges. Then take a craft knife and spin it inside the holes at the ends of the tube to remove any burrs of metal.
12. Position one of the 1/4” tubes against the edge of the lid, where it will be soldered. Hold in place with long tweezers. Apply a small amount of flux to the foiled edge and copper tube, solder into place. Flux and solder the remaining surface of the tube and the foiled glass edge, avoiding the openings.
13. Next, thread the inner tube (rod) through the opening of the soldered tube. Slide the remaining 1/4” tubes onto either end of the rod. Position the lid on top of the base, flux the outer tubes and solder them to the base of the box. Make sure the top portion has free mobility. Solder all portions of the remaining outer tube including the outer openings to ensure the inner tube (rod) does not slide out.
14. When the box has cooled, wash with warm soapy water and dry.
15. Apply black patina to the soldered areas of the box, following the manufacturer’s instructions.