Pioneers in the 1800s didn't have access to electricity like we do today. So if they needed to walk somewhere or do something in the dark, they couldn't use a flashlight; instead they used a lantern with a candle or gas flame inside. One common type of lantern was made of punched tin. Below are some examples.
To make the lanterns, craftsmen would first punch holes or various sizes and shapes into tin plates, then the would use various tools to cut and bend the plates into the shapes you see above.
For requirement #2 of the Our Heritage badge (learn how to make a craft from pioneer times), we'll make a simplified punched metal lantern. Instead of making holes into flat tin plates, we'll make the holes into aluminum cans that are already in the shape we want. And we'll have to do something else that the pioneers didn't do -- fill the cans with water and then freeze the water. Otherwise if we try to pound holes into an empty can, it will buckle and dent from the pressure. The hard, solid ice will help the can keep its nice round shape.
For your Simplified Punched "Tin" Lantern, you need:
- an empty 14-oz can
- a paper template (and maybe a pencil or marker, if you want to draw your own design)
- tape
- a dish towel
- a screw (works better than a nail because it's usually pointier/sharper)
- a hammer
- a battery-operated tealight
The process
Step 1a) Note: this may take a day or more. Wash out the empty can. If there are sharp bits at the top from where the lid was removed, consider flattening those with a pliers. Fill the bottom 1" or so with water and place the can upright in the freezer. Once the water is frozen, fill the can a little more than halfway, freeze again, and finally fill it to the top and freeze again. (If you fill and freeze the can all at once instead of incrementally, the bottom may bulge due to the expansion of so much water during freezing.)
Step 1b) While you're waiting for the water to freeze: Print out one of the template pages -- the first page. (or use the one supplied).2: If using the supplied paper pattern, pick whether you want to do the star or the heart. Wrap the paper pattern around the can so your desired design isn't partially covered and tape paper to paper to hold it in place. (Tape won't stick to the cold frosty can.)
If using your own pattern, cut a letter-size paper in half "hotdog-style" (i.e. lengthwise, so it's 11" x 4.25"). Wrap around
Step 2) Wrap the paper template around the frozen can and tape the paper to itself so it doesn't move. (Tape won't stick to the frosty can!)
Step 3) Rest the frozen can on its side on a towel so it doesn't roll away. Turn it so the part of the design you want to work on is facing up. Using the dots on the paper to guide you, gently tap the screw with the hammer to punch holes that follow the dot design. Turn the can as needed so the dots you're currently working on are facing up. Continue until you've punched all the holes.
Step 4) Dunk the can in a bowl of hot water to melt the ice enough until the block can be dumped out. Allow the can to dry. (Note: Do not dry the inside with a cloth as the punched holes are sharp!)
Step 5) Turn on the tea light, then drop it into the can. Avoid lowering your hand into the punched can; it's like a grater in there!