Simple & Awesome Halloween Bats

To be perfectly honest, I never thought that these bats would be as huge a hit as they have become over the years. When I first started this project, I was just messing around with some empty beer cans before throwing them in the recycle bin. I have always been a tinkerer and I wanted to come up with something fun to make with an empty can. It was close to Halloween, so I naturally opted to do something seasonal. The first thing that came to mind was bats. I love bats and owls. I free-hand drew a silhouette of a bat in flight on paper. (I have included the silhouette in this Instructable) I cut it out and traced it on a sheet of aluminum I had managed to cut from an empty can. The rest is history.

Once I had completed a handful of these bats, I casually handed a few to friends and coworkers and what happened next, no one could have predicted. Everyone wanted them! I got to making them day and night and by the time Halloween arrived I must have made and handed out over a hundred bats that first year. Since then, it is an annual ‘expectation’ from my little workshop by people all over the country (yes, I ship them to friends and friends of friends of friends, you get the idea, via mail all over the country). On average I make a thousand bats, 100% by hand, each year just for fun. Over the years I have experimented with all sorts of different paint jobs, personalization’s, you name it. So try this project and give them out and see if it doesn’t happen to you. Everyone loves getting these hand-made bats and you will delight in their smiles!   

For this project (of ONE bat) you will need:

• An empty aluminum can (soda, beer, coffee, etc.)
• Half-Bat pattern *NOTE: You will only need 1 can per bat. To start off you will need a can specifically to cut a pattern to use for all the bats from then on. You will only need one can for the pattern cut out
• Stiff wire (I only use utility flags from the local hardware store - cheap and perfect for this)
• Can of black spray paint (Flat, Semi-gloss or Gloss depending on your likes)
• Clear All-Purpose glue (Gorilla Clear is best but just about any weather-proof glue will work - not hot glue)
• Hammer
• Ball point pen
• Tin Snips (Technically called Aircraft Shears but for this Instructable I call them tin snips)
• Scissors
• Pliers
• Clothes pin (the kind with a spring)

For this project there are 3 things that can go wrong:

1. Use of hot glue- DON'T!
2. Overbending the bat belly crease
3. Not letting the glue dry vertical

Here is the now world famous (just kidding) pattern I drew years ago. What is great about this is it makes the perfect size bat. Plus, it is the largest bat you can make with a sheet of aluminum from a standard 12 oz. can. So, either print this pattern up or try to free draw your own (it's not hard but the finished pattern should be 4 inches long). Yes, it is only 1/2 a bat. I will get to that later on. For this, just cut out this half of bat on paper.

Now you need to make your first sheet of aluminum. You will use this technique from now on when your 'cull' (cut up) the cans. I highly recommend you use a decent pair of work gloves for this step to prevent the so-easy cut hands. These edges will be razor sharp. This part is not for the kids.

Take the first empty can and your tin snips. Tin snips make this very easy since cutting through the reinforced top edge of a can is rather strong. DO NOT try to use scissors!

You will first insert the tin snips into the top opening to cut to the shortest edge of the hole to the outside of the can. Make a 'snip' cut through the top edge ring all the way to the outside edge of the can where the sides begin to curve in towards the top.

Move over to the other edge of the drink opening and do the same step to make a second snip.

Once you have made two (2) cuts, you will insert the tin snips into the cut open edge to rotate the cut all the way around the top of the can. I find it easier and more consistent to follow the top of the label on the printed can. That eliminates the bend in the top portion of the cut can. You do not need the curved top/bottom. You are going for a flat single piece.

Once the top has been completely cut off, cut down the straight line of the label (it is always on the can where both ends of the label meet - aka: the back) cutting all the way to the bottom of the can.

Finally, you will cut the bottom of the can off in much the same way you did the top, following the printed label edge to make it nice and straight.

You should now have your first sheet of aluminum ready to make a pattern.

Now you will trace the bat you drew or cut out of paper. This is a one-time thing so keep the aluminum pattern you make in this step for future bat making.

Take the piece of paper you either drew or printed up and trace with your ball point pen the half-bat on the aluminum sheet you just cut. It does not matter where you place it to trace it. Not in this step. Just make a nice aluminum pattern you can use. You do not have to have ink on it, just the indentation from your ball point pen is enough for you to follow when cutting. I used a previous pattern already in aluminum for this Instructable in the picture, but you get the idea.

NOTE: Don't worry, I used a picture of a folded sheet for this. You don't need to do that. Just a half-bat will do.

For any of you 'corner cutters' I have to tell you, drawing out the entire bat will not only be a lot more cutting and work, but the wings will not be consistent, and you will get truly frustrated. A HALF-BAT is best. Trust me.

After you have traced the half-bat, use your regular scissors and carefully cut the half-bat out. Do not worry about ragged edges or irregular edges. They will be hammered out next.

For this part you see I have a full bat folded. You do NOT. The step here is the same so just ignore the folded bat. Just grab a piece of scrap wood or other solid surface (a cutting board would work fine) and gently tap out all along the cut edges (you do not have to hammer like a maniac, a simple tap will do). You will immediately see how gentle tapping will completely smooth out the edges and make a beautiful half-bat pattern.

Now that you know how to 'cull' the empty cans go ahead and do it again until you have a single sheet of aluminum.

Once I get going 'culling' the cans I end up with a stockpile for future bats. :)

1. Gently fold the sheet in equal half but DO NOT bend the center all the way flat. Leave it fairly loose. The fold will be the center of the bat. If you smash it down completely flat the aluminum will break in two.
2. Once you have a fold, position the pattern with the belly edge of the bat half on the folded edge.
3. Trace around your pattern until you have a copy that you can see enough to cut.

Now cut the trace out while the sheet stays folded so you have an exact duplicate on both sides making a complete two-winged bat.

DO NOT unfold completely. The less you work the aluminum fold the better. More folding and unfolding will separate the sheet into two sections.

You will tap out the edges while the cut is still folded like you did the first time with the initial pattern. DO NOT pound, hit or smash the folded edge! Pretend there is a straw or something underneath the edge. Just tap out the other 3 sides of the wings, just not the 'belly' of your bat.

Flip over and tap out the edges again so you have tapped all 3 edges, both sides.

The edges should be remarkably smooth now with no jagged edges.

Now the fun part. Holding the new bat by the 'belly' with one hand, gently use your other hand to slightly unfold the bat's wings all the while using your own flair, gently round the wings out until you have what looks like a bat in flight. *As long as you hold that folded edge, you can bend the wings as far as you want. Experiment. I like to vary some bats with wings up and some with them down. You will discover your preferences as you get hooked on this.

In this step I prefer to use utility marker flags not only because they come in packs of 100, but they are inexpensive, and the wire is so strong and perfect for this project I cannot imagine using anything else.

Simply strip the little flag off the wire with a knife (any will do) and toss the flag. We don't need it.

Take the wire and mark at 4 inches from one end.

Or, if you want to, place the wire in the fold of the bat and mark the point where the bat's tail ends, and the wire starts.

Bend the wire at a 45-degree angle at that point.

Set the bent end of the wire into the fold of the bat's belly. You may have to pinch the fold to hold the wire until the next step.

Take the clothes pin and pinch the base of the bat's tail to hold the bat in place. In my experiences, it is important to pinch the base of the tail (and nowhere else) so all the glue (in the next step) will not run out.

*This next step is easy, but you have to consider:

• Where you will set the bat/wire to dry so drips of glue will not drip on anything important.
• The bat MUST BE IN A VERTICLE POSITION while the glue cures.

This step will not work if you lay it on its side to dry. It has to be standing upright. I live at the beach, so I just stick them in my yard (sand) to hold them upright. You might want to try filling a cup with sand, dirt, instant rice or gravel. Use something you can stick the wire into while the glue cures.

• Once you have pinched the tail, starting at the top (the bat's head) slowly dribble about an eye dropper amount of glue into the channel where the wire is sandwiched in the bat.
• Stick the bat/wire into your holding material and leave it alone for several hours or overnight (whatever time it takes to dry/cure the glue you use). Do NOT use hot glue!

Any drips of glue that emerge from the tail are not an issue. They will follow the wire down and disappear.

Now it is time to release the bat from the clothes pin. Once the glue is dry, remove the clothes pin (if it is also glued, carefully squeeze the clip as hard as possible to release), or carefully twist it free.

Once you have the clip off, once again use your hands to gently shape the wings into the shape you want (like back in Step 10). If any glue dripped down the wire you can simply pick it off easily.

Now you should have a secure, new bat that will flap its wings with any movement of the wire.

Finally, you get to spray paint your bat whatever color you want. I use different types of spray paint for various people and variety. For this first bat, let's use a satin black paint. It's inexpensive and has that traditional spooky black bat kind of vibe. I have had great results with High-Gloss black paint but sometimes a shiny black bat doesn't fit the need. I also pepper my painted bats with a dusting of traditional orange flat paint to give it a splash of color. I even dust them with a clear glitter spray for a really eye-catching look. I once did a bunch using textured, granite-look spray and the bats looked like they were made out of stone. How cool! You are only limited by your imagination at this point so go for it!

Spray all sides and don't forget the wire. It needs paint too.

Time to enjoy your new bat! As I mentioned, I use different colors for different folks. I personally love to give out 'bouquets' of bats to friends (a dozen or so in a bunch). *Idea: Tie the bunches together with inexpensive black lace from the discount store with extra hanging from the bow for a more eye-catching presentation. You can try orange ribbon, blood red for a dramatic twist, raffia, sisal twine, whatever will contrast and make your creations pop.

A last word of advice and I'll get outta here: Do not use a hot glue gun to attach the wire to the bats. The heat of the glue will burn your hand through the aluminum immediately on contact just as if you put the hot glue directly on your fingers. Additionally, the hot glue will not hold to the aluminum. It might at first, but a little movement and it will pop free.

Do not get discouraged if your bat making doesn't go right the first time or even a few times. Like I mentioned, I have been doing this for many years and trust me when I tell you I have made many, many mistakes. As you can see, I work in hundreds of bats at a stretch (and you will too once you start handing them out) and as you progress you will find it easier each time.

Good luck and thank you for joining me on this journey. It has been my pleasure. Let me know how yours turn out and the reactions from the people who get them as gifts!