How to Make Punched Tin Signs

Metal punching is a popular way to create a variety of arts and crafts, including luminaries, cabinet doors and signs. The simplicity of the process and the beauty of the finished result helps to make metal punching a popular craft. You can use copper, tin and brass craft foil to create your projects, or you can recycle leftover roof flashing or tin cans to make decorative home and garden designs. To make punched tin signs, you can punch a pattern of letters and imagery using printed or stenciled patterns.

• 1

  Unroll the 5 mil tin craft foil to the desired length of the sign. You can also use metal flashing from the hardware store if you need a wider sign. Cut the tin to the desired sign size with tin snips.

• 2

  Attach the cut tin to a 1-inch thick or thicker wood board that is larger than the overall sign size. Use a tack in each corner of the tin to attach it to the wood.

• 3

  Tape the paper design outline or letter stencils onto the tin with painter's tape. Painter's tape can be removed easier than other adhesives.

• 4

  Trace the stencil outline onto the tin with a washable marker. There is no need to transfer the design to the tin if you are using a paper outline, since you can insert the nails through the paper.

• 5

  Position a finishing nail in the top corner of the sign design outline. Use a larger nail if you prefer a larger hole. Hit the nail with the hammer hard enough to penetrate the tin. The nail will also go into the wood slightly; pull it out.

• 6

  Position the nail 1/8 to 1/4 inch from the first punched hole along the design outline. Punch another hole through the tin.

• 7

  Repeat steps 5 and 6 to punch holes along the entire sign design outline. Space the holes evenly. Remove the paper outline or wash away the remaining marker lines.

• 8

  Remove the tin sign from the board. Fold a strip of duct or electrical tape over each side of the sign to eliminate the sharp edges. You can also nail the sign to the backside of a wood frame.