I found these wonderful instructions from Erica McPhee on her website at Paperwhite Studio. Although you can tweak the size of your pen, it's great to have these specific measurements to start out.
*I have made some changes to these that I note below.
Here is a link to print out hers:
https://paperwhitestudio.com/wp-content/uploads/2013/09/folded-soda-pen.pdf
Materials:
- Metal. You can use any type of material you wish, however, I suggest starting out with soda/pop can as it's easier to fold (see notes at the bottom for cutting) and you probably have some on hand. Later, you can try Metal Flashing (which is sold in the Roofing area of home improvement stores -- e.g. Lowes) -- see pics below.
- Ruler
- Fine pt. perm. marker
- Scissors or Shears
- Dowel of some sort to hold the nib (I usually use an old pencil, but you can use a paint brush, or nib holder, etc.) Just make sure it's something comfortable for you that you'll be ok holding in your hand, and not too small or big for the metal.
- Tape. I use Duct Tape, but masking or painter's tape is fine too.
- Sandpaper
*Note: Do NOT use a can of "Lime-a-Rita" as pictured above. 😆😵 I didn't realize how flimsy it is until I compared it to a Coors Light can (which I've used for my other pens -- I call those my "beer" nibs.) :D
*Also: Be careful when cutting the metal, as it's sharp! And I always try to cut above a waste basket b/c of misc. metal shards. Be sure to clean up well after too.
Follow her instructions and your pen should turn out wonderful! **Just note the changes I've suggested:
Tips
1. The measurements do not have to be exact. Close enough if good enough. (These are just better than none!)
2. Do NOT make notches as noted in Step 5! This will ruin your pen (or rather, it will weaken the metal and it will bend -- see my pic below):
*It still works, but now I have to hold at a different angle and manipulate it differently than a regular pen.
3. If you're using a pencil, do NOT sharpen it (and if it's already sharpened, cut it down and sand it to flatten the end -- as shown in the instructions), otherwise, the end and lead will break off and clog your pen. (I learned this the hard way!)
4. I suggest folding slightly before taping to the dowel (before Step 7), as it will fit a little better and be easier to attach.
5. When you're ready to cut, Start at the TOP and cut down toward the holder. Otherwise, if you cut from the bottom, it will bend the nib end.
6. Sand it so it's not sharp and won't cut the paper when lettering. Hopefully when done, your pen should look like this:
First Homemade Folded Pen I made that turned out! (using Erica's instructions) See how straight it is compared to my store-bought nib below:
Here is what Metal Flashing looks like:
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It's in the shape of an L/corner piece. There are different thicknesses, so you may want to "test" a piece, as some aren't as pliable as others. A tad harder to work with than aluminum, but not too bad!
More nibs from Metal Flashing.
(ugh, my lettering! This is a few years b4 it started improving.)
*How to Fix a Folded Pen (see post):
To Cut a Soda or Beer can:
1. Once empty, rinse well and let it dry.
2. Cut off one end of the can first (I "puncture" it carefully with the scissors or an old knife). Again, BE CAREFUL as the metal's sharp!
3. Cut down the side of the can to the bottom then
4. Cut off the other end. (*You may have to dry the inside.)
5. Try to lay out and flatten the metal as best as you can (I wrap it the opposite way around another cylinder, and leave it overnight, then bend it myself to straighten).
*If using metal flashing, buy the most pliable stuff. It's easier to work with and bend yet more sturdy than soda can.
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