Recycling Scrap Into Sheet Metal

by Judy Larson

When rising precious metal prices left Judy Larson carefully rationing her sheet metal, inspiration struck! Remembering a past experiment with melting and recycling scrap, she decided to turn small leftover pieces into usable sheet metal, proving that even the tiniest scraps can have a second life. Discover how this simple technique can stretch your materials and spark new creative possibilities!

Instructions

Step 1

When melting down scrap metal for pieces that will be sold, separate out any items with solder residue.

This ensures that the remaining metal can be hallmarked with confidence.

Judy Larson's Recycling Scrap Into Sheet Metal - Step 1, Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, ensures that the remaining metal can be hallmarked

Step 2

I wanted to make 24-gauge sheet metal.

Since I wasn't sure how much metal I would need for a small piece, I started creating scrap piles of around 4 grams and gradually increased the amount.

I labeled each nugget and photographed the finished sheet pieces.

This process gave me a better idea of how much metal to use for future projects.

By the end of the experiment, I found that 10 to 11 grams of scrap produced sheet pieces the size I would most often use.

However, the larger the sheet, the more likely cracks will appear along the edges. This is something to keep in mind.

Judy Larson's Recycling Scrap Into Sheet Metal - , Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, make 24-gauge sheet metal

Step 3

Since I was experimenting, I melted scrap on three different surfaces.

Try all three to see which is easiest to use and best suits your needs.

Magnesia Soldering Block:

Be careful when melting metal on this block.

As the metal melts and balls up, it can pick up dust from the surface, creating small pits that only appear after rolling the metal out.

Solderite Board:

On a new board, the metal melts well and moves easily without picking up surface bits.

However, melting in the same spot a second time can cause the metal to stick and pull some board material with it.

Placing scraps on unused areas and sprinkling a little water on hot metal helps release it cleanly.

Charcoal Block:

Metal can pick up tiny bits of the block as it balls up, similar to the magnesia block.

Since charcoal retains heat longer, it also takes more time to flatten the balled metal with a solder pick.

Melting Tips:

When melting scrap piles with a butane torch, use a solder pick to release air bubbles trapped between pieces.

One of my piles had a large hidden air pocket that kept bubbling until I cut it in half with the pick to let the air escape.

Once the scrap has melted into a molten mound, scrape the pick across the surface to start flattening it.

Pull the flame back slightly as you flatten, then remove it completely and make one or two more passes with the pick.

Don't worry if the surface looks grainy.

Allow the pieces to cool on the soldering surface. They can be moved to a bench block while still hot.

Judy Larson's Recycling Scrap Into Sheet Metal - , Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, Placing scraps on unused areas

Judy Larson's Recycling Scrap Into Sheet Metal - , Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, Pull the flame back slightly

Step 4

After the flattened nuggets have cooled, brush the bottoms with a soft steel brush to remove any soldering surface residue.

Do not worry if the bottoms are not perfectly flat or smooth.

Judy Larson's Recycling Scrap Into Sheet Metal - Step 4, Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, remove any soldering surface residue

Step 5

Place the nuggets one at a time on a bench block.

Use a 2-pound dead blow brass hammer to flatten each as much as possible.

This process work-hardens the metal, so the pieces will only become slightly thinner.

If you are lucky enough to own a high-end rolling mill, continue to Step 8.

Step 6

If you do have a rolling mill:

Since I own an inexpensive rolling mill with rollers just under 3 inches wide, the thickness and size of metal sheets that can be made are limited.

Pieces that are too large, too thick, or not annealed enough can stress the gears and parts, potentially causing cracks or breakage.

It's wise to anneal the flattened pieces and then repeat Steps 4 and 5.

A magnesia soldering block works well for this because the metal isn't being melted.

Anneal the pieces until they reach an orange color.

Even if no residue appears on the bottoms, brush the cooled pieces with a soft steel brush if needed.

Repeat Step 5. The pieces will grow in diameter as they become thinner.

Pieces between 2mm and 2.5mm thick work best for starting the rolling process with my mill.

The annealing and flattening process may need to be repeated depending on your rolling mill.

Repeat as many times as necessary.

Judy Larson's Recycling Scrap Into Sheet Metal - Step 6, Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, Repeat Step 5

Judy Larson's Recycling Scrap Into Sheet Metal - Step 6, Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, Repeat as many times as necessary.

Step 7

What if you don't have a rolling mill?:

The pieces in the first and second photos were mostly 5-gram pieces.

The third and fourth photos show an over 1,400-year-old half follis coin featuring Flavius Mauricius Tiberius Augustus.

The flattened pieces resemble ancient coins with irregular edges.

Add a face by hammering a laser-cut ancient coin likeness onto a well-annealed piece.

With patina, it will look a bit like an authentic ancient coin.

Judy Larson's Recycling Scrap Into Sheet Metal - Step 7, Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, mostly 5-gram pieces

Judy Larson's Recycling Scrap Into Sheet Metal - Step 7, Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, 1,400-year-old half follis

Judy Larson's Recycling Scrap Into Sheet Metal - Step 7, Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, Flavius Mauricius Tiberius Augustus

Judy Larson's Recycling Scrap Into Sheet Metal - Step 7, Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, flattened pieces resemble ancient coins

Judy Larson's Recycling Scrap Into Sheet Metal - Step 7, Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, Add a face by hammering

Step 8

Anneal the discs.

Step 9

My practice was to run the pieces through the rolling mill first in one direction, then the other.

The rolling mill wheel was tightened 1/8 of a turn at most, usually less.

The pieces were flipped over and the rolling process repeated.

Flipping the pieces helps keep them flatter, rather than following the curve of the roller.

Judy Larson's Recycling Scrap Into Sheet Metal - Step 9, Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, Flipping the pieces helps keep them flatter

Step 10

Repeat Steps 8 and 9.

Watch for cracks in the edges of the rolled pieces.

All small cracks will become larger (blue arrows) the thinner the piece is rolled.

To avoid this, cut or file away small edge cracks before they grow.

Why did I let the cracks in the piece on the right get so large? I wasn't paying attention and didn't expect a tiny crack to turn into a crater in one pass through the rolling mill.

How to minimize cracks: Rolling the metal in the direction of the stress crack can help.

With the piece on the right, this wasn't possible.

The edge with the crack can be melted back, which thickens the metal as it pulls together.

Hammer the piece to an even thickness before rolling it again.

Once a piece is wide enough for use, stop rolling in both directions as in Step 9.

Roll the metal only in one direction.

Step 11

Continually check the thickness of the sheet by sliding the piece into the slots on an American Standard or SAE wire gauge.

Continue to anneal, roll, and check the sheet until the desired gauge is achieved.

Step 12

Pickle the pieces. Neutralize them in a baking soda and water solution when removed from the pickle.

Rinse and dry the pieces before use.

Note: You may choose to pickle the pieces between steps.

Any pickle residue on the rollers, even if dry, can damage them over time.

It's a good idea to clean your rolling mill rollers often, especially after making small sheet metal pieces.

Simichrome is my preferred roller cleaner, but other products will work as well.

Step 13

I was pleased with the small pieces of sheet.

I had some .999 silver metal clay pieces that didn't turn out.

Could they be melted down and made into bezel strips? It was worth a try.

Yipee! It worked and was cut into bezel strips!

Step 14

Since one side of a few small sheet metal pieces was less smooth or mirror-finished than the other, I decided to anneal all the pieces.

I textured the side that was least smooth on each piece.

The three textured sheet metal pieces shown were all that remained after using recycled metal for the rest of the tutorial pieces.

Here's what I made using the recycled metal, a WIN in my book!

Judy Larson's Recycling Scrap Into Sheet Metal - , Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, black bracelet

Judy Larson's Recycling Scrap Into Sheet Metal - , Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, red bracelet

Judy Larson's Recycling Scrap Into Sheet Metal - , Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, pendant and earrings

Judy Larson's Recycling Scrap Into Sheet Metal - , Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, pendant front

Judy Larson's Recycling Scrap Into Sheet Metal - , Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, pendant back

Judy Larson's Recycling Scrap Into Sheet Metal - , Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, pendant variation

Judy Larson's Recycling Scrap Into Sheet Metal - , Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, pendant variation 2

What about all the scraps left from making these pieces?

They were made into sheet again, with a bit more scrap and water cast rejects added.

Many pieces were rolled only to a 20-gauge thickness, as I wasn't sure what I would make with them.

I use 22- and 20-gauge sheets for pendants, while earrings are generally made with 24-gauge.

Check the photos to see how large a 10-gram piece becomes when rolled out to various gauges of sheet.

Judy Larson's Recycling Scrap Into Sheet Metal - , Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, Many pieces were rolled

Judy Larson's Recycling Scrap Into Sheet Metal - , Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, 10 gr 14 g

Judy Larson's Recycling Scrap Into Sheet Metal - , Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, 10 gr 16 g

Judy Larson's Recycling Scrap Into Sheet Metal - , Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, 10 gr 18 g

Judy Larson's Recycling Scrap Into Sheet Metal - , Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, 10 gr 20 g

Judy Larson's Recycling Scrap Into Sheet Metal - , Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, 10 gr 22 g

Judy Larson's Recycling Scrap Into Sheet Metal - , Metalwork, Stamping, Stamps, Butane Torch, Soldering, Solder, 10 gr 24 g

Materials

Argentium silver sheet scraps

Lesson Quantity: 1.00 pieces
Purchase Quantity: 1.00 each

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Tools

Deluxe Soldering Kit

G15-5

G15-5
Lesson Quantity: 1.00 pieces
Purchase Quantity: 1.00 each
Price: $116.97
Gold Club Price: $87.73

Add to Bag

Rolling Mill 80mm

MIL-280.10

MIL-280.10
Lesson Quantity: 1.00 pieces
Purchase Quantity: 1.00 each
Price: $349.95
Gold Club Price: $262.46

Add to Bag

Bench Blocks - 130 X 130 X 20

DUR-1187

DUR-1187
Lesson Quantity: 1.00 pieces
Purchase Quantity: 1.00 each
Price: $66.67
Gold Club Price: $50.00

Add to Bag

AWG American Wire Gauge for All Sizes of Wire - Pack of 1

G7-8

G7-8
Lesson Quantity: 1.00 pieces
Purchase Quantity: 1.00 each
Price: $11.95
Gold Club Price: $8.96

Add to Bag

Dead Blow Brass Hammer - 2 lb. Brass Hammer

HAM-456.20

HAM-456.20
Lesson Quantity: 1.00 pieces
Purchase Quantity: 1.00 each
Price: $32.97
Gold Club Price: $24.73

Add to Bag

Digital Tabletop Balance and Counting Scale, 1000G

SCL-292.50

SCL-292.50
Lesson Quantity: 1.00 pieces
Purchase Quantity: 1.00 each
Price: $80.00
Gold Club Price: $60.00

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Steel Brush

BRS-967.00

BRS-967.00
Lesson Quantity: 1.00 pieces
Purchase Quantity: 1.00 each
Price: $8.25
Gold Club Price: $6.19

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Brass Caliper - Gemstone And Bead Measuring Tool

G7-9

G7-9
Lesson Quantity: 1.00 pieces
Purchase Quantity: 1.00 each
Price: $8.97
Gold Club Price: $6.73

Add to Bag

Liver of Sulphur Gel, 1 Ounce Bottle

SOL-610.01

SOL-610.01
Lesson Quantity: 1.00 pieces
Purchase Quantity: 1.00 each
Price: $9.95
Gold Club Price: $7.46

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Category: Metalwork
Technique(s): Stamping, Butane Torch Techniques

Reviews

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Judy Larson

My philosophy has always been "I will never live long enough to learn everything I want to learn, go everywhere I want to go and see everything I want to see!" So, what I make and how I create it is always changing and evolving. I was born shortly after WWII to parents who grew up during the Depression. They always had a "we can do it, we can make it" attitude which rubbed off on my two younger brothers and me. My brothers are amazing and can make and do ANYTHING! When I was a little girl, my mother gave me an old carved cigar box, which I cherish, filled with pop beads, wooden beads and yarn for stringing. That was the beginning of my jewelry making journey.

On a visit to the Grand Canyon when I was a young woman, I was fortunate enough to help a Native American silversmith sand cast my first silver bracelet and bezel set a large turquoise nugget on top. I was in love, hook, line and sinker! While working full time and having a family here in northern Minnesota, my artistic endeavors slowed down but never stopped. I am an artist, scrapbooker, seamstress, woodworker and jewelry artisan. Now that I am retired, I am able to indulge in all my hobbies. However, there just never seems to be enough time in the day to do it all, but I try!

I have been teaching community education beginner and intermediate jewelry making classes since my retirement. Many of my students have been bitten so hard by the jewelry making bug that they say I have turned them into monsters-they just can't get enough. Making jewelry, seeing something take shape from small bits and pieces, is so rewarding that I hope it brings out the "monster" in you, too!