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Page 2: Aluminum Bottle in Cups

Roll a rim on an Aluminum Bottle to create a Tumbler Cup, or a Cook Pot fora backpacking stove.

This instructable walks through the process of making a mouth-friendly edge onan aluminum bottle turning it into a Cool Reusable Metal Tumbler Cup.

The steps outlined here are, stand-alone, instructions to make a complete MetalTumber from an aluminum bottle; suitable to use as a lightweight tankard for allyour favorite beverages.(I recommend the chilled kind. Remember science?...aluminum is an excellentheat conductor; you don't want hot cocoa burns on your fingertips as well as thetip of your tongue!)

However... those of you familiar with the Aluminum Bottle BackpackingStove,( http://www.instructables.com/id/Aluminum-Bottle-Alcohol-Stove/(http://www.instructables.com/id/Aluminum-Bottle-Alcohol-Stove/) ) will alsorecognize the technique demonstrated here, as a means for creating light weightcooking tools to accompany an alcohol stove.

The video below shows these Aluminum Bottles & Tumblers in use as alightweight backpacking cook / storage system.

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Aluminum bottle (/tag/type-id/category-outside

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alcohol stove/)

backpacking (/tag/type-id/category-outside/keyword-

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backpacking stove (/tag/type-id/category-outside

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backpacking gear (/tag/type-id/category-outside

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Aluminum Bottle AlcoholStove(http://www.instructables.com/id/Aluminum-Bottle-

How to lighten your pack.(Backpacking)(http://www.instructables.com/id/How-to-lighten-

Kpot...and alcohol stove(http://www.instructables.com/id/Kpotand-alcohol-stove/?utm_source=base&

Pot Stand-Windscreen(http://www.instructables.com/id/Pot-Stand-Windscreen/?utm_source=base&

Camp Table forBackpacking(http://www.instructables.com/id/Camp-Table-

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Step 1:

I have gotten inquires about the availability of this style aluminum bottle.The bottles are obviously used for beer (and I know at least one soft drink)however, availability of either (or any for that matter) varies by region.

As an added note: I had reservation about posting an instructable that featuredan alcohol container as it is not appropriate for all. I would have perfered to usea soft drink bottle however due to availability in my area, I only have found thebeer bottle variety.But ultimately, its the aluminum bottle that we're interested in, notnecessarly the beverage. Dispose of the contents as you deem appropriate, orseek out empties through another source.

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(Along the same lines: I am pretty sure not everyone who has built a bar-b-quefrom a steel barrel personally bought, and consumed the 50 gallons of Crude Oilinside to get to an empty drum.)

Step 2: Cut the Neck Off

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Cut the neck off the bottle at the location shown in the picture. It should be at thefull diameter of the bottle; below where the neck starts to taper.

Aluminum bottles are a thicker gauge than aluminum cans so utility knives won'twork.

I use a hack saw to cut the bottle. Cut around the diameter rather than trying tocut straight through. The saw teeth will catch on the edge of the bottle and leaveragged edges.

Step 3: Start the Flare

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The edge of the bottle needs to be rolled back on itself 2 times this tuck thesharp edge under the second roll and away from contact during sipping.

Start to flare the edge of the bottle. A 1" diameter wooden dowel works well.

Start by placing the dowel in the bottle so it is resting on the bottom. Rotate thedowel around the edge of the bottle.

Use a "stirring" motion as you press the dowel outward against the bottle's edge.

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Gradually pull the dowel up off the bottom of the bottle while stirring to increasethe angle of the bend.

Step 4: Rolling the Edge

Flare the bottle with the dowel until the bottle has a flange as shown.

At this point, place the bottle on a flat surface. A soft wood surface works well.The bottle will slightly press into the soft wood giving it some grip. This helpskeep the bottle from slipping while rolling.

Tilt the bottle it so that only a portion of the edge is in contact with the wood.Press down on the bottle and rock it in a circular motion; keeping only a smallportion of the edge in contact with the wood at any given time.

The second photo shows the rolling in a sequence of pictures

Do not try to do all the bending in one rotation.

Gradually increase the downward pressure on the bottle as you roll it aroundseveral times. You want a nice controlled edge without any kinks or variation inflange length.

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The third photo shows the flange after rolling

Step 5: Increase the Roll Angle

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As the Flange starts to roll back on itself, gradually increase the angle of thebottle slant while continuing to rock the bottle around

Eventually you will be rolling the bottle almost on its side to get the cut edge ofthe flange as close to the bottle's side wall as possible.

Step 6: Closing the Edge(http://cdn.instructables.com/FPF/FKSW/FZG4366O/FPFFKSWFZG4366O.LARGE.jpg)

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Use the wooden dowel to finish working the cut edge of the flange against thebottle side wall.

The edge needs to be "tucked in" for the start of the next roll. The goal is to notcollapse the cross section of the rim with a hard crease. The edge wants to curlinward.

Step 7: Second Roll

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Start to flare the rim for the second roll.

Use the dowel to flare the rim just like for the first roll. Then rock the cup on a flatsurface just like before.

Be careful that the first fold does not coming unrolled as you start the secondflare and roll. The cut edge needs to be tucked into the second roll.

Reference the second picture.

Step 8: Finish

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Again use the dowel to finish pressing the second roll tight against the can.

Adding just the start of a third flare, will help to close the gap between thesidewall and the second roll.

Stretch the rim by placing the dowel in the bottle and repeat the stirring motion.This will bring the rim back from any "out of round" bending that might haveoccurred.

The stretching also increases the "hoop tension" on the rolled rim to finishpulling it tight against the side wall.

The photos show the finished product with a tight fitting rim.

Step 9: Ready to use

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You now have an aluminum Tumbler cup. Just fill it with your favorite beverage.The heavier wall thickness of aluminum bottles adds just the right amount of heftto the feel.

The finished Tumbler won't crush or have that "oil can" flex like aluminum cans.They feel, and look like any other tumblers you could use and store in yourcupboard.

Go ahead, make a whole dinner service worth of them!

Step 10: Additional Camp Use.

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We have a be nice comment policy.Please be positive and constructive.

I Made it! Add Images Make Comment

(/member/camping+crazy/)

1 year ago Reply

(/member/spark+master/)

4 years ago Reply

(/member/TheLimbReaper/)

4 years ago Reply

This Tumbler also works as a Storage Cover and Cook Pot for an AluminumBottle Alcohol Stove.

The video in step 1 shows both of these in action.

There are designs for aluminum can cook pots however they don't compare tothe strength and durability of an aluminum bottle.

The Stove Instructable found at this link.http://www.instructables.com/id/Aluminum-Bottle-Alcohol-Stove/(http://www.instructables.com/id/Aluminum-Bottle-Alcohol-Stove/)

Note: Because the cooking pot also stores the stove, the bottle was stretched tofit over the stove before the edge was rolled.

1-40 of65

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camping crazy (/member/camping+crazy/)

These are awesome!!! But you shouldn't cook in them, aluminum gives offreally bad chemicals when heated. But still they are awesome and areprobably fine for occasional use!!

spark master (/member/spark+master/)

incredible, I thought you would need to fire the rim first, it might even behelpful. I wish I had gotten into making these BEFORE the bottles becameextinct!

can't really get them here on LI w/o extreme expense, and if you do not likeBud, (me), or can't drink anymore anyway , (me) , then y'all screwed. I wouldlove to try this out . Anyone out there know of any place out here that sell it onpremise , so I could try to scrounge them ??

thanks

chris

TheLimbReaper (/member/TheLimbReaper/) spark master

In Pennsylvania I first saw the aluminum bottles atthe local bar for a special event. Mostly I don't seethem at the bar but now the beer distributer sellsBud alum. bottles by the case. I suggest checkingat your local drinking establishments, that is ifyou're still allowed to enter.

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4 years ago Reply

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1 year ago Reply

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spark master (/member/spark+master/) TheLimbReaper

Hi Limb Reaper, DAD BURNIT IT! I found yourreply the day I got back from Pennsylvannia !!AARRGGHH I even passed two beer distributors. Igotta say I hate Budweiser so I would never havebought the stuff, do they have Deposit bottlesthere? sparkie

TheLimbReaper (/member/TheLimbReaper/) spark master

Ha, I'm hot a big Bud fan either. No we don't haveany deposits in my area North of Pittsburgh. Isuggest buying a case and gifting it on the conditionthat the receiver returns the bottles to you.

Grey_Wolfe (/member/Grey_Wolfe/) TheLimbReaper

I did almost this very thing.

Having wanted the bottles for awhile to make the various Ible goodies, Ifinally found them at the local Safeway.

Bought a case for our anniversary BBQ and just told everyone to putthe bottles back into the box when they were empty.

Still got a bottle sitting in my fridge waiting for someone with differenttastes to visit, but I got my bottles. :D

spark master (/member/spark+master/) Grey_Wolfe

By next year I am told Dinkle Acker will re debut here in USA...no cans,but drinkable beer/pilsner

TheLimbReaper (/member/TheLimbReaper/) Grey_Wolfe

Wow! This was such an old post I almost forgotabout it. I haven't messed with the stoves for a while.My design ideas ran their course I guess. I'm stillsitting on a handful of the good bottles just in casethough :-)

TheLimbReaper (/member/TheLimbReaper/) Grey_Wolfe

Wow! This was such an old post I almost forgotabout it. I haven't messed with the stoves for a while.My design ideas ran their course I guess. I'm stillsitting on a handful of the good bottles just in casethough :-)

spark master (/member/spark+master/) TheLimbReaper

Hi, Good Idea, gone flat. Anybody I know that Iwould willingly give a caser of beer to (at a veryhigh price), would not be caught dead with a Bud intheir hands. All of us drink german stuff. This weeka big special by us is buy a case of HoffbrauOctober fest, get a 1 liter Stein (glass, not clay :-( )

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5 years ago Reply

free. I have two now, (or soon will, they owe me one). I may buy a few (if Ican find them) and just dump them out. I can drink maybe two then theydestroy me, bad hamngover or futzie head next day. Drink the Deutch stuff,no worries. I just wish I had gotten your email B$ I left PA , I passed twobeer distributors on way home. Of course in PA one must buy "cases" froma beer distributor, here in NY it is wacko, but I can buy onsies and twosiesin a BD. ttfn sparkie

JoshuaSmock (/member/JoshuaSmock/)

Venom Energy drinks come in thick aluminum bottles, as a non-alcoholicalternative, also it's made by Dr Pepper Snapple so it's widely available.

Grey_Wolfe (/member/Grey_Wolfe/) JoshuaSmock

Venom are one of my preferred crafting bottles as well. The resealabletop is a huge plus. And they aren't as narrow as the beer bottles.

However the bottle is not nearly as sturdy as the Bud and Coke bottles.Also, and this is my main reason for seeking out other sources thanVenom, they do not have a bottom shape that allows them to be usedeffectively as a die.

tinkrtur1 (/member/tinkrtur1/)

I contacted Budweiser HQ and gave them my zip code. They provided me withthe names of places to purchase their beer in my local area. You might want totry the same with coca-cola, pepsi-co, coors, etc.

AbbieX (/member/AbbieX/)

Dollar Tree sells cheapo aluminum water "bottles" for...you guessed it...$1!Yeah, I would rather go this route than to choke down a budmiloors!

WayfinderAli (/member/WayfinderAli/)

a few matching pairs of these would make a great inexpensive weddingpresent if you have friends that are big drinkers. We have friend who areHUGE drinkers and wish I could have made them some for their recentwedding.

nodnol (/member/nodnol/)

What kind of lining is in the aluminum bottle? Doctors and food safetyspecialists often say not to store food or beverages in opened aluminumcontainers, or re-use the containers because the aluminum may leach out.Aluminum consumption is linked to Alzheimer's Disease. However, if the bottlehas a protective lining, it should be ok to re-use.

hpstoutharrow (/member/hpstoutharrow/) (author) nodnol

I believe most metal food and beverage containersare sprayed with a food grade epoxy coating toprevent contact (and chemical reactions) betweenthe food and metal.

mrsayao (/member/mrsayao/) hpstoutharrow

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5 years ago Reply

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a-watt/)

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5 years ago Reply

Some cans are lined with BPA. Theuse of BPA has become a hugedebate. The food packagingindustry is clearly for the use of BPAas it does exactly what you two arestating, however the flip side of thedebate mothers, doctors havebegun to voice their experienceswith it. Canada has begun to banthe chemical in all food gradecontainers. It's sad to come to knowthat since a lot of things in this worldcan cause cancer, it would beextremely difficult to stay away fromeverything that is "cancer causing."I'm against BPA use, but I amTOTALLY for these aluminumtumblers!!! Good job, I've alwayswanted to know how to roll analuminum lip like that!

kill-a-watt (/member/kill-a-watt/) mrsayao

My understanding is that the entire industry is phasing out that type ofplastic liner for all types of cans. I think I saw a news story on that onlya few weeks ago.

jaberwok32 (/member/jaberwok32/)

hpstoutharrow , I think your instruckable is fantastic. I made thebackpackstove, it works great. I have a question though, when I try to roll theedge of the tumbler, I get to the point when you work it on the wood, the lip isbeveled out flat and when I start the rolling over process on the first roll Iconstantly get a crack . Im having trouble getting the first roll to lay flat againstthe can. Ive tried so much my fiance is beginging to think Im an Alcoholic. Lol Am I putting too much pressure? Going to fast? If you could enlighten methat would be great. Im sure your an expert and these are just amaturemistakes but I would really like a tumbler set lol.Thanks

hpstoutharrow (/member/hpstoutharrow/) (author) jaberwok32

A few split when I first started. I hope somethinghere helps:1. Make sure the cut edge is free of saw nicks,burrs, and file marks. There should be no edgeimperfections that could initiate a crack.2. The cut edge should be flat. After any cutting orde-burr filing turn the edge on emery cloth placedon a flat surface. Removing material this wayeliminates high spots on the edge and ensures theedge has a full wall stock thickness.(see the first photo below)3. When the flare is started make sure the edge isnot too wide.4. When rocking the bottle on the wood to roll theedge, do it gradually and evenly. It will take anumber of turns. Periodically stop and examine theedge to make sure it is rolling evenly. Adjustdownward pressure accordingly.5. Make sure the bottle stays round while rockingthe bottle do not apply so much downward force

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4 years ago Reply

that the edge of the bottle takes on an extreme oval shape. Stopoccasionally and use the dowel or push bottle over the neck end of anotherbottle or use a PVC pipe connector (photo 2 below) to "stretch" the edgeback into round.

Good luck and keep trying. Let me know if you succeed.

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/F2Y6QP3FYNTA0WE.LARGE.jpg) (http://cdn.instructables.com/FOL/1JZV/FYIYO9OR/FOL1JZVFYIYO9OR.LARGE.jpg)

TheLimbReaper (/member/TheLimbReaper/) hpstoutharrow

Ah gee, looking at your pics. I guess I can't addmuch useful as I too figured out to use the PVCcollars also. I can suggest to use the shortenedbottom of a "cottle" and a leather mallet to helpform an "inside" rolled lip. This works especiallywell if the bottle bottom is streached first. Alsosome single use propane cylinders (Worthingtonbrand) when cut open (extreme caution warning: Becertain cylinder is completely empty before cuttingopen) have a dished bottom wish is handy informing an internal bead. The "forming" can bottommust have a small hole drilled in it to avoid avaccum. I hope that's helpful to somebody.

TheLimbReaper (/member/TheLimbReaper/)

I wouldn't get too excited about posting the "beer bottle" stove since mostkiddies know what beer is. I do have to agree with the comments against usingthe cans as the primary cooking vessel as they certainly are lined (at least thesoda cans). With that said; I have thrown caution to the wind and made acoffee percolator from Bud bottles myself.

lostdragon (/member/lostdragon/)

I wouldn't use one of these to cook anything in. They are usually lined withsomething that isn't made to be heated and you'll end up eating it. Somebodye-mailed Heineken in a different 'ible about making a cook pot out of their beercans and they replied with as much. Be careful.

TANZMEISTER (/member/TANZMEISTER/) lostdragon

They're lined with plastic. Though any that will vaporize will burn off thefirst time you use it. And you don't eat the flames (I hope).

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TANZMEISTER (/member/TANZMEISTER/)

using another bottle as a pot is a neat concept. However, it seemsthat with the flames racing up the sides your losing at least halfyour heat to the surrounding system rather then transfering it toyour desired heat reservoir (your pot). If having better efficiency isnot an issue, then using the bottle as a pot is great. If betterefficiency is an issue, then I'd recommend a pot with a larger base,twice the diameter of the heat source is usually recommended forgas camp stoves. your pot design is still the best I've seen here oninstructcables!

TANZMEISTER (/member/TANZMEISTER/) TANZMEISTER

fail! I ment to say stove design at the end there

SasquatchKid (/member/SasquatchKid/)

Great ible

ch5 (/member/ch5/)

Awesome!I didn't think that putting such a neat finish on the borders could be done byhand without some kind of weird specific tool.I'm doing this to my alcohol stoves soon :)

Thanks a lot.

kimbe mtumbo (/member/kimbe+mtumbo/)

Quite cool. I wish I had a set of these.

junits15 (/member/junits15/)

what brand of soda uses these?

smn368 (/member/smn368/) junits15

there were a few limited edition mt dew and other pepsi products thatwere in the same bottles

junits15 (/member/junits15/) smn368

as soon as i read, "limited" i went, DARN

Father Christmas (/member/Father+Christmas/) junits15

The "Venom" brand energy drink also uses thesebottles.

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Father Christmas (/member/Father+Christmas/) FatherChristmas

speaking of the Venom brand, i bought two last night andremember mentioning them here. So, naturally, I followedthis instructable lol

(http://cdn.instructables.com/FZG/9BE3/G3KYBH5C/FZG9BE3G3KYBH5C.LARGE.jpg)

hpstoutharrow (/member/hpstoutharrow/) (author) Father Christmas

Nicely done! The Venom graphic looks great as acup.

Father Christmas (/member/Father+Christmas/) hpstoutharrow

I agree. I am contemplating buying the otherflavours just for the purpose of a full set, to give asgifts to those certain people who are obsessed withenergy drinks..

hpstoutharrow (/member/hpstoutharrow/) (author) Father Christmas

I found some Mt. Dew aluminum bottles withHalloween designs this last October. How's this asan "eye for an eye". Though I think I like theVenom eye better.

(http://cdn.instructables.com/FHO/8631/G3KYGJB9/FHO8631G3KYGJB9.LARGE.jpg)

Father Christmas (/member/Father+Christmas/) hpstoutharrow

ha! Eye for an Eye! That was pure genius! I neverwoulda thought of that! :)

hpstoutharrow (/member/hpstoutharrow/) (author) junits15

I received comments there are bottles of MountainDew. I have not found them myself.

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