Can I Make This Iconic Lighter? Part 1

[@TimothyDyck]

Thanks for the shout out! Can’t wait to see how this series unfolds. I love these lighters to. Keep the forge lit eh! 🔥💪

[@jreererer8490]

Mate i LOVE your vids!

[@anthonyp4209]

I was so stoked to see this as well. Well deserved wait shout out. Love your channel

[@jimmyrk3]

Alec needs a new ax to make those bends...

[@mrscary3105]

I watch you too! :)

[@Brettkob]

I was about to link that! So cool.

[@harrygunther6381]

Definitely gonna be a 50 part series! Can't wait lol

[@realberserkpanda]

I would still binge watching several times when I get high lol

[@StopaskingformynameYouTube]

Considdering it's more than one episode per part at this point, yup.

[@justinwilson4454]

50?!?! I think your low balling it lol

[@cleverusername9369]

@@realberserkpanda it sucks that my zippo isn't really conducive with my bong

[@dooomi2824]

When i saw the Video in my feed i was wondering how this was a multi-part series. After watching the first two minutes i musst say i was very wrong!!

[@598Hans]

I have five years experience as designer of constructions from bended sheet metal. I see three major mistakes. 1. too small radius on dies, 2. no lubrication of sheet before forming 3. don't hamer it, press it. Change these three thing, and you'll see better results.

[@TankToChest]

Hello fellow nerd here. The shock of the hammer is stretching it? That’s what I was assuming. Yes! Lubricant 🤘🏻🤘🏻🤘🏻 I’d guess he needs to smooth Champher the top so it gradually forms the top. Also couldn’t the die just be half an inch long. Does it really need to be shoved in so far. What matters is just the two corners at the bottom right. Less friction?

[@598Hans]

@@TankToChest In this case, the stretching of material is negligible. The issue is creating the stress concentration spots. That is why, forming of sheet metal, is always done in one smooth stroke. A force and heat from friction is much better displaced through the material. That mean better chance to avoid stress marks, like its rippling, cracks or stretching (like you said). A deeper die is beneficial for this type of bending. Because it is more in area of forming than bending. And friction is solvable by lubrication of material. But is absolutely possible to use shallow die. But result would be probably less desirable.

[@598Hans]

And radius of the bevel on the die needs to be corresponding with a thickness of the material. Good rule of thumb is 2.5-3x thickness of the material as a mininimal radius.

[@Merennulli]

What does the lubrication do for the process? I knew vaguely that it was a thing in metal bending, but I've never known why. My assumption was that it allowed it to move against the die without as much friction along the sides as it bends, thinning and straining the material at the bend. I've only done metal bending for home projects and making cosplay props. My methods were amateur, but they were more akin to Adam Savage's recommendation of gradually bringing the radius down in tiny increments.

[@598Hans]

@@Merennulli Your assumption is correct. And following recommendations of Adam Savage is good thing to do. His experience with fabrication are priceless for diy projects.

[@DavidGuyton]

I love this lighter kind of content. I can't hold a candle to this kind of work. Straight fire! You're about to light up the internet with this one. The heat is on now. Ok I'll stop.

[@stookinthemiddle]

Yeah you should zip it. The spark has gone from the joke - Wick you need to do is tinder your resignation. Case closed.

[@DavidGuyton]

@@stookinthemiddle hahahahahahaha perfection

[@AlecSteele]

😅😅😅

[@hi-nl4ev]

I haven't heard that song for decades but have been singing it for two days before your comment, "Old flames can't hold a candle to you"

[@rileyharriss5542]

Alec should get all the youtube blacksmiths together and do a sword collab. Each person makes one part, (blade, guard, handle, pommel, decoration) and then sends it to the next with no guidance, so the next person up has to look at style clues to get the same look. Give no direction to each other either, kinda like how they used to do it, where each part was made individually.

[@tylerakerfeldt7220]

Someone tried to do this between some of the machining channels on KZbin and it failed epically.

[@singer3188]

Yes! Then send it through a round of youtube sword reviewers. Starting with Skallagrim haha

[@sithus1966]

@@tylerakerfeldt7220 Where was it last seen? NY CNC?

[@urielachilleus3159]

love seeing things get handmade hat are typically mass-produced! very cool project :)

[@deadstickdave9479]

Zippo collectors across the world, we have found the perfect maker for inserts of zippos. Great project Alec.

[@DonariaRegia]

It feels like this build could benefit from the use of a small hand brake. Somewhere down the road try making a Roman compound utensil, the "original Swiss army knife" from about 1700-1800 years ago. I've made a couple and they are a challenge.

[@justin.booth.]

Has he ever nade a swiss army knife? If not that would be really cool to see!

[@VorpalGun]

@@justin.booth. He can't, he would make a British army knife.

[@willharris-braun4422]

@@VorpalGun this is the kind of thing i read the comments hoping to see but never do

[@weoff507]

Yay. I’ve been waiting on a 49.5 part mini series from Alec Steele for a long time. This is gonna be awesome.

[@onlyadog]

The little bits that bulge out at the bottom of the inner casing have a purpose Alec! I believe they are there so the inner casing can be undersized compared to the outer casing can still result in a snug fit. Possibly make a slightly undersized bit of sheet and put the bumps in with a cold chisel that way you don't have to design around perfect tolerances? Great work as always tho!

[@timtaylor-medhurst9665]

I wonder if those ribs are also to add rigidity into the sides to prevent them from bowing?

[@brandonolson1959]

I literally scrooled through to see if anyone else was thinking this same thing

[@Lynkah]

Timothy Dyck is fantastic. He's one of my favourite youtubers, alongside Alec Steele, ofcourse! Timothy Dyck makes incredibly good quality usable axes if anyone ever wants one.

[@secretsquirrel726]

There were different numbers of holes around the chimney, that changed in the late 1940's. I suggest you cut the holes to look different than the circles, like file them into stars or make slit-like square ones. I always thought a small bend in the top of the lighter case would make it easier to locate and handle in a pocket, set right in the middle. The number of hinges for the case changed from 2 to 3 to 4 hinges, mainly during the 1940's and 1950's. The US patent numbers were different, and WW2 ones are mostly known by their patent date changes. Letter and number abbreviations on the bottom of the case gave general information about when batches were made. The US Marine and WW2 black crackle Zippos are very sought after. The sealant in the top of the case is very important, because the fluid tended to evaporate out quickly. One of my Zippos will hold a charge of fluid for a couple of weeks. In comparison a competition Sherman lighter from WW2 I have I will only hold fluid for about 3 days.

[@jaquigreenlees]

The Zippo I bought about a year ago has a B ZIPPO 20 for the code The 1 hinge is 3 tines one one side 2 tines on the other. It has 8 holes on each side of the chimney. I bought a spring clip leather Zippo Case for it, holds the lighter upright and easy to access with a waistband clip of spring steel to keep the case in place.

[@HavocHounds1988]

One of the things I love about your channel is you work like a true blacksmith. If you don't have the tool to make something, you don't just buy it for the most part, you make it yourself.

[@Doc-Holliday1851]

Your dedication, self motivation, and enthusiasm throughout a challenge you came up with just to test your own skills are all incredibly inspiring.

[@sv8me]

you know what really look cool is scale it up alec do a 1-4 scale up but has to be fully functional now that would be more fitting for black smithery

[@NBCRGraphicDesign]

It might be easier to make a Hippo. Know the difference between a Hippo and a Zippo? A Hippo weighs-in at 2000lbs., while a Zippo, is a little lighter

[@collinarnold9178]

Huge advocate of Tim’s! He’s such a good guy, and his content is chill as can be. One of those KZbinrs that you’d SWEAR has a bigger following.

[@jarheadpig8912]

I’ve never had any interest in blacksmithing or knife making, but I can’t get enough of your videos. It’s really cool how you tackle difficult projects specifically to target skills you need to improve.

[@andrewbettcher7856]

It is truly amazing. I think I’m like most people who watch this. I wish I had the knowledge, tools and fortitude to make stuff like this. Even with all that, I’d would probably give up after a few failures and order the footage to be destroyed and threaten to sack anyone who mentioned the doomed project. That’s what makes these videos so good. He just keeps trying until he gets it right. A lesson for all of us.

[@rayza1982]

This is why I love your videos. “I don’t have this tool so I’ll make it.” Brilliant!

[@Supreme-King]

For projects like this he should really consider a small scale laser cutter, good for thin sheet metal. It may sound like a waste of money but when you spend a few days making blanks just to break them during testing it starts to even out, time tends to be a lot harder to come by.

[@timtaylor-medhurst9665]

Totally agree. May ditract from the ground up, in period, hand made approach though? I'd go CAD and laser cutter if given this challenge.

[@2stroke_fanatic357]

Funfact: I am a toolmechanic who workes in a german company, that manufactures the special press tools for Zippo. Besides Zippo, we also have contracts with Pringles, Coca Cola, Pepsi Cola, Aptamil and so on. Quite interesting to see a one man tool shop replicate the complex tools, that are usually designed by a whole team of engineers.

[@TimothyHall13]

Oh Yeah!!! Thanks Alec!!! Zippo is the best. Iconic sound of one opening and lighting followed by the clap of the cover closing.

[@tomaszto]

I love the idea of recreating the whole thing!!!

[@robertmccracken72]

Alec, just let me say good luck. I worked for Zippo in the 90's making the wheel, screw, flint tube and tip. All of those parts are made in house and the wheels are undercut and then flame hardened to be able to make a good spark. The press that stamps out those insides makes the earth move under your feet every time it cycles... I can't wait for the next instalment.

[@Robenbuilds]

This is going to be a interesting project, looking forward to see how it unfolds!

[@ezekielortega6040]

Heck yeah Timothy and Alec! Both of my favorite blacksmiths !

[@beautifulsmall]

Great to see you taking on a project most of us probably have little experience of but sheet metal work is so universally used its a great choice. Would love to see more dimensions and numbers.

[@folklorequine]

Ignore the snidey comments, this is why I love your content, it actually encourages US to find out more as you did yourself! Alec, you rock!

[@GiraffeFlavored]

Yessss, just finished binging the sword-breaker series, gotta love when you finish one and see a brand new video, hot off the press!

[@PhiceT1917]

I'm not even a smoker, a Zippo is part of my EDC. Im partial to the brass bodies, but I love any design. Great to watch you build one

[@onurdabanca4095]

When i saw the video's title i've been shocked. Because that product is really really giving pleasure for me (smoking kills kids, please drop that quickly.) and beside you are already working on them. This is great interest, thank you for the handle of this beauty.

[@wade-potato6200]

I got a zippo a few years ago and man I love that thing. And I like how they guarantee it forever and they intend you to use it forever

[@rustjupiter]

Have you ever seen an old school hinge bending jig? You could make a rectangle the size and shape of the lighter and then add a notch in the side to the side of said rectangle to hold the streak at the seam. Maybe I could make a video with paper if you’re interested.

[@brandonquintana9943]

My grandfather gave me one that his father gave him. My grandfather served in Korea from 49-52 and his father served in ww1 and 2. Still have it. Love it!

[@noahbessman5063]

I think what I admire most about watching your channel is your dauntless dedication to the tasks that you both lack skill in and detest doing. Your attitude toward improving your skills and always seeking to make things the very best you can is an inspiration; keep it up!

[@UnclePsychedelic]

This is gonna be one of the greatest series so far:D can’t wait to the next episodes

[@HBontekoe]

Hi Alex, it's important to note the Rolling direction of the material. Bending perpendicular to the Rolling direction would prevent cracking of material, if you bend parallel to the Rolling direction the grain of the material can not withstand the bend and easily cracks. Especially with tight corners. Good luck with the project. Like to see the finished project!

[@Zeo_Kana]

loved watching you try new things and really push yourself into areas of weakness which is the only way we improve. I love the attitude of "i need this... but different, i'll make it" most people would have brought another bend tool but not you. :)

[@jpdthe3rd]

Sheet metal break! As well as leave a little more clearance in the swage

[@dincirkic4974]

always wanted to see this, also Alec, when you draw around a shape it will usually be around a millimetre larger than the actual thing because the sketching tool used will almost always have something kinda spacing it, you can see this at 1:42 and it seems your be your problem at 9:17.

[@modularcuriosity]

You're so right about that sound. My grandfather was a pipe smoker and that sound always reminds me of him.

[@adamjohnson5307]

Your dedication to figuring things out is inspiring man

[@jstperfect]

am a Zippo collector and this interests me so much can't wait for part 2

[@TheWolfster001]

You need a mini metal brake to do it.. I made one over 30 years ago to restore a very old lunchbox.. You should be able to buy one or just get plans for one and scale it way down to build a miniature version...

[@brianriddle8389]

This is really cool! Can't wait to see how it turns out.

[@rainmannoodles]

This is a really cool project and I'm excited to see the process (and the final result!) I think one thing that will be obvious throughout is the difference between hand-made and mass-produced designs. The Zippo is meticulously optimized to be easy to make... for a machine. The way it's assembled is repeatable and tolerant to flaws, but is difficult (but not impossible) to reproduce without bespoke tooling.

[@WilliamDuckett]

I'm about 5 minutes in, from what I know about sheet metal manufacturing they probably stamped the holes, then stamped the share with the chimney bends and then a final shape is pressed on some kind of block the same size as the finished lighter, power hammers were a godsend and out manufacturing of small precise objects went through the roof when they became more available.

[@melody3741]

My absolute favorite thing is when people try to tackle commercial production methods at home. I don't know why I love it but it's just so interesting. The commercial and industrial fields are usually just so far disconnected from normal people that you never get to see how they do it and to see how much work went into it.

[@joeyzuppardo3110]

Everytime Alex posts I remind myself of one of the better decisions in my life of subscribing to this channel I love this stuff want to eventually get into blacksmithing and this is great motivation

[@leekent7493]

This is fundamentally what my dad did. He was a press tool designer. Flat metal in one end shaped finished piece out the other. Sometimes hundreds per minute. Look forward to the next stages !

[@g-rod5199]

This is awesome, I love watching the breakdown of everyday items and seeing the complexity of what someone else went through in design. Excited to see the final one!

[@rgoodwinau]

Great tribute to Zippo, and the complexity of mass producing something that looks simple and intuitive to use!

[@FrankCalisch]

The dedication to growth and facing down your weaknesses are inspiring! Great project

[@codym2903]

Makes you appreciate the amount of work it takes to design and mass produce such "simple" everyday items.

[@svetislavcosovic5715]

This is going to be the best series on KZbin. Loveee it 😍

[@jayera8053]

Totally looking forward to this build series, keep it up Alec 🙌

[@thereasoninlifeisthatthere5326]

Thats what I am learning. I am a toolmechanic apprentice (sheet forming and stamping) in my second year.

[@diamonddogie]

About the bending parts that are too short, you can easily make them longer and then cut to size

[@giggityguy]

For the very small folds, wouldn't it just be easier to make your blank longer than it needs to be, fold it, then cut it to size? It certainly seems like making small bends is harder when you don't have much leverage or space

[@Paleoman52]

I've been to the Zippo Lighter factory. It is about 50 miles Southwest of where I live in Western New York State. They also make Case knives in that same factory. There is a great museum of the history of the Zippo Lighter in that factory. You should visit this place someday.

[@jonathanlunger2775]

This is SO EXCITING much love from a Pennsylvanian that can't wait to see this awesome blacksmith make an amazingly classic design

[@troywalker8078]

MULTI-PART SERIES!! YAY!!

[@mastuve]

I smoked for years when I was younger and I had a black zippo with a Harley Davison brass buckle wrapped around it... I quit smoking 11 years ago but I still have that Zippo

[@tankerboysabot]

The fact that you have the patience to even figure this out in such a short amount of time amazes me.

[@notold37]

Definitely a tough project, but if anyone can do this, I know Alec can, it does look frustrating, and as a sheetmetal worker myself, your doing a bloody awesome job, 👍🏼👍🏼👍🏼👍🏼🇦🇺🇦🇺🇦🇺🇦🇺🦘🦘🦘🦘Cheers from Melbourne Australia

[@GodLovesUsSoMuch]

Shaping up to be a fun project! Appreciate seeing the trial and error and method to progress. God bless brother!

[@Buddha23Fett]

I have at least 6 zippos with various inserts from butane to electric to ones sealed to reduce fuel evaporation. By far the best lighter design on the market.

[@justindoubikin6384]

Along with all the other comments I'm keen for a 50 part series, I'm also super keen for this series it will be very informative

[@jeffreycarter1223]

I don’t think I’ve ever been so excited about a series

[@DanielEleveld]

Oh man- next time you have to cut an angle into some stock, just put it into a machinist vice and clamp that vice onto your mill vice. Nodding the head is the most headache inducing way to do that. Anyway, can’t wait to see this project! You are the best!

[@shelbykingnfs7216]

8:44 that cut was absolutely hilarious!

[@andyaitken4243]

Fair do’s there’s only a very rare, token few young people who would even want to attempt this build. Alex isn’t just a blacksmith, he’s a bladesmith, a KZbin content creator, a business owner, a tool maker and everything else in between. I’m pretty sure he can even cook well too. I can only sit here and wish I had his drive at his age, I just turned 49yo on Friday and I’m in awe of his skills and work ethic.

[@cosmicbrambleclawv2]

I don't think I've clicked on a Steele video so quickly before (and I click on them mighty damn quickly 😂) Super excited to see this one

[@therealcavegoblin]

I've used zippos for years and I've always wondered how they were made. Fantastic work!

[@jasonmead8475]

This is excellent. Truly a pleasure to watch you figure it out.

[@otterconnor942]

This series is the one that might actually make me want to give what you did a try

[@zachreimer4262]

You should definitely make a damascus case at the end that would be the cherry on top.

[@leviathan7477]

The metal shaping reminds me of the collab a little while back between Ron Covell and This Old Tony on the dustpan.

[@Wreckz_Tea]

I honestly miss seeing him make knives. I enjoy his other videos as well but I can't wait to see some new knives designed my alec

[@Tokahax]

A note on engineering your dies: don't forget to add clearances for the width (twice the sheet thickness) of your work material. Looks like you're opening up the jaws with your sheet metal.

[@dylanpritchard4981]

I like how small and intricate this build is going to be!

[@FKreider]

Now this is my kind of Alec Steele content!

[@rosscammell2701]

That’s what I love about watching blacksmithing. Don’t have the right tool? Make one!! Wish I had the skill and knowledge

[@victoriaeads6126]

I've been to the museum in Bradford. It is both fun and informative, with a charming whiff of American Roadside Attraction. I highly recommend a visit.

[@forester6335]

Have been watching you for years now and your content always continues to be incredible. I would love to see if you can make a compound bow in the future. As always keep up to amazing work.

[@anurag_swain]

Another series yet another decade... Loved it❤

[@asheddie]

Excellent project to take on. Interesting to learn it was an Aussie who came up with the original idea.

[@Byrtie21]

That's a lot of work for mock-ups and tooling! Great video, as always! Side note: if you make it with that iconic Zippo *ping* sound, make sure it's not exact. Zippo actually owns the rights to the sound a Zippo makes

[@filstewart2380]

I too love Zippo lighters. They now make a butane insert, and I'm a total convert... Thanks for the great video.

[@danispewak3219]

The Zippo Museum and store in Bradford PA would be well worth the visit! They have a repair shop and you can watch metalsmiths repair Zippos at all states of disrepair!

[@G1-D3-0N]

See the process and trial and error makes me happy. Life is full of trial and error until we get it just right.

[@masterpython]

There are instructions for coiling springs on a lathe in the Machineries Handbook. It gives wire and mandrel sizes as well as the TPI for a few sizes. Not sure about tiny ones.

[@linkthehero5314]

This is going to be favorite series bc I love zippo lighters

[@ilikaplayhopscotch]

Those machines that do the material-in-one-end-finished-product-out-the-other thing are pretty handy! You should look into gettin one of them.

[@entropy11]

Incredible, pushing your limits like this. Love it.

[@firebird8600]

Zippos are my favorite! I keep my 2nd ever zippo in a leather holster on my belt every day. (Even though I do not, and have never smoked)

[@funguy123hs]

I learn that prototyping is very crucial in pre production, so we can adjust the dimension of the item we want to make

[@jchristjohn]

Great video as usual Alec, been a fan for a few years now! Just wanted to pop in and let you know I was born and raised in Bradford, PA and have family and friends that have worked at Zippo. There is a pretty sweet museum near the factory. When you get back to the US you should check it out!

[@ff-qf1th]

This is an exciting new project! I can't wait to see more.