aluminum bottle cook pot

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http://www.instructables.com/id/Aluminum-Bottle-Tumbler-Cup-Cook-Pot/

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Aluminum Bottle Tumbler Cup & Cook Pot for an Alcohol Stoveby hpstoutharrow on September 9, 2009

Table of Contents

Aluminum Bottle Tumbler Cup & Cook Pot for an Alcohol Stove ...........................................................................

Intro: Aluminum Bottle Tumbler Cup & Cook Pot for an Alcohol Stove ...................................................................

Step 1: ..................................................................................................................

Step 2: Cut the Neck Off .....................................................................................................

Step 3: Start the Flare .......................................................................................................

Step 4: Rolling the Edge .....................................................................................................

Step 5: Increase the Roll Angle ................................................................................................

Step 6: Closing the Edge .....................................................................................................

Step 7: Second Roll ........................................................................................................

Step 8: Finish .............................................................................................................

Step 9: Ready to use ........................................................................................................ 1

Step 10: Additional Camp Use. ................................................................................................ 1

Related Instructables ........................................................................................................ 1

Comments ................................................................................................................ 1
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Intro: Aluminum Bottle Tumbler Cup & Cook Pot for an Alcohol StoveRoll a rim on an Aluminum Bottle to create a Tumbler Cup, or a Cook Pot for a backpacking stove.

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

The steps outlined here are, stand-alone, instructions to make a complete Metal Tumber from an aluminum bottle; suitable to use as a lightweight tankard for all yourfavorite beverages.(I recommend the chilled kind. Remember science?...aluminum is an excellent heat conductor; you don't want hot cocoa burns on your fingertips as well as the tip of ytongue!)

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

The video below shows these Aluminum Bottles & Tumblers in use as a lightweight backpacking cook / storage system.
http://www.instructables.com/id/Aluminum-Bottle-Tumbler-Cup-Cook-Pot/http://www.instructables.com/id/Aluminum-Bottle-Alcohol-Stove/


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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 featured an alcohol container as it is not appropriate for all. I would have perfered to use a softdrink bottle however due to availability in my area, I only have found the beer bottle variety.But ultimately, its the aluminum bottle that we're interested in, not necessarly the beverage. Dispose of the contents as you deem appropriate, or seek outempties through another source.

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

Step 2:Cut the Neck OffCut the neck off the bottle at the location shown in the picture. It should be at the full diameter of the bottle; below where the neck starts to taper.

Aluminum bottles are a thicker gauge than aluminum cans so utility knives won't work.

I use a hack saw to cut the bottle. Cut around the diameter rather than trying to cut straight through. The saw teeth wil l catch on the edge of the bottle and leave raggeedges.


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Step 3:Start the FlareThe edge of the bottle needs to be rolled back on itself 2 t imes this tuck the sharp 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 the dowel around the edge of the bottle.

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

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


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Step 4:Rolling the EdgeFlare 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 helps keep thebottle 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 small portion of thedge 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 around several times. You want a nice controlled edge without any kinks or variation in flange

length.

The third photo shows the flange after rolling

Step 5:Increase the Roll AngleAs the Flange starts to roll back on itself, gradually increase the angle of the bottle slant while continuing to rock the bottle around

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


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Step 6:Closing the EdgeUse the wooden dowel to finish working the cut edge of the flange against the bottle side wall.

The edge needs to be "tucked in" for the start of the next roll. The goal is to not collapse the cross section of the rim with a hard crease. The edge wants to curl inward


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Step 7:Second RollStart 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 flat surface just like before.

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

Reference the second picture.


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Step 8:FinishAgain 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 the sidewall and the second roll.

Stretch the rim by placing the dowel in the bottle and repeat the stirring motion. This wil l bring the rim back f rom any "out of round" bending that might have occurred.

The stretching also increases the "hoop tension" on the rolled r im to finish pulling it tight against the side wall.

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


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Step 9:Ready to useYou now have an aluminum Tumbler cup. Just fil l it with your favorite beverage. The heavier wall thickness of aluminum bottles adds just the right amount of heft to thfeel.

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 your cupboard.

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


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Step 10:Additional Camp Use.This Tumbler also works as a Storage Cover and Cook Pot for an Aluminum Bottle 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 to the strength and durability of an aluminum bottle.

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

Note: Because the cooking pot also stores the stove, the bottle was stretched to fit over the stove before the edge was rolled.
http://www.instructables.com/id/Aluminum-Bottle-Alcohol-Stove/


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Comments

50 comments Add Comment view all 57 commen

kage_no_akiri says: Dec 11, 2010. 10:39 PM REPhly crap this is ACE! next time i go to town im gonna look up a few places and see if icn find any bottles like this. i need to replace my current stove cus itburns too much fuel compared to yours. it takes 40ml of methanol to bring 350ml of water up to temp for my tea. i love the tumblers you presented here aswell. ive never seen a rolled edge done this way and im hoping ill be able to pull it off. thanx so much for this.

oh yes, i also wanted to thank you for recording your films w/o sound. it was a lot easier to focus on the demonstration in silence. the notations were alsovery brill.

WayfinderAli says: Sep 20, 2010. 10:49 AM REPa few matching pairs of these would make a great inexpensive wedding present if you have fr iends that are big drinkers. We have friend who are HUGEdrinkers and wish I could have made them some for their recent wedding.

nodnol says: Sep 24, 2009. 8:20 AM REPWhat kind of lining is in the aluminum bottle? Doctors and food safety specialists often say not to store food or beverages in opened aluminum containers, re-use the containers because the aluminum may leach out. Aluminum consumption is linked to Alzheimer's Disease. However, if the bottle has a protectivlining, it should be ok to re-use.

hpstoutharrow says: Sep 24, 2009. 3:13 PM REPI believe most metal food and beverage containers are sprayed with a food grade epoxy coating to prevent contact (and chemical reactions) between tfood and metal.

mrsayao says: Sep 25, 2009. 11:42 AM REP

Some cans are lined with BPA. The use of BPA has become a huge debate. The food packaging industry is clearly for the use of BPA as it doesexactly what you two are stating, however the flip side of the debate mothers, doctors have begun to voice their experiences with it. Canada hasbegun to ban the chemical in all food grade containers. It's sad to come to know that since a lot of things in this world can cause cancer, it would beextremely difficult to stay away from everything that is "cancer causing." I'm against BPA use, but I am TOTALLY for these aluminum tumblers!!!Good job, I've always wanted to know how to roll an aluminum lip like that!

kill-a-watt says: Sep 2, 2010. 4:48 AM REPMy understanding is that the entire industry is phasing out that type of plastic liner for all types of cans. I think I saw a news story on that only afew weeks ago.

spark master says: May 10, 2010. 2:20 PM REPincredible, Ithought you would need to fire the rim first, it might even be helpful. Iwish Ihad gotten into making these BEFORE the bottles became extinct!

can't really get them here on LIw/o extreme expense, and if you do not like Bud, (me), or can't drink anymore anyway , (me) , then y'all screwed. Iwouldlove to try this out . Anyone out there know of any place out here that sell it on premise , so Icould try to scrounge them ??

thanks

chris

TheLimbReaper says: Aug 21, 2010. 3:57 PM REPIn Pennsylvania I first saw the aluminum bottles at the local bar for a special event. Mostly I don't see them at the bar but now the beer distributer sellsBud alum. bottles by the case. I suggest checking at your local drinking establishments, that is if you're still allowed to enter.

spark master says: Aug 24, 2010. 5:23 AM REPHi Limb Reaper, DAD BURNIT IT! I found your reply the day I got back from Pennsylvannia !! AARRGGHH I even passed two beer distributors. Igotta say I hate Budweiser so I would never have bought the stuff, do they have Deposit bottles there? sparkie

TheLimbReaper says: Aug 24, 2010. 2:25 PM REPHa, I'm hot a big Bud fan either. No we don't have any deposits in my area North of Pit tsburgh. I suggest buying a case and gifting it on the

condition that the receiver returns the bott les to you.

spark master says: Aug 24, 2010. 6:17 PM REPHi, Good Idea, gone flat. Anybody I know that I would willingly give a caser of beer to (at a very high price), would not be caught dead with aBud in their hands. All of us drink german stuff. This week a big special by us is buy a case of Hoffbrau October fest, get a 1 liter Stein (glasnot clay :-( ) free. I have two now, (or soon will, they owe me one). I may buy a few (if I can find them) and just dump them out. I can drinkmaybe two then they destroy me, bad hamngover or futzie head next day. Drink the Deutch stuff , no worries. I just wish I had gotten youremail B$ I left PA , I passed two beer distributors on way home. Of course in PA one must buy "cases" from a beer distributor, here in NY it wacko, but I can buy onsies and twosies in a BD. ttfn sparkie
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jaberwok32 says: Oct 8, 2009. 10:14 AM REPhpstoutharrow , I think your instruckable is fantastic. I made the backpackstove, it works great. I have a question though, when I try to roll the edge of thetumbler, I get to the point when you work it on the wood, the lip is beveled out flat and when I start the rolling over process on the first roll I constantly get acrack. Im having trouble getting the first roll to lay flat against the can. Ive tried so much my fiance is beginging to think Im an Alcoholic. Lol Am I puttingtoo much pressure? Going to fast? I f you could enlighten me that would be great. Im sure your an expert and these are just amature mistakes but I wouldreally like a tumbler set lol.Thanks

hpstoutharrow says: Oct 8, 2009. 7:01 PM REPA few split when I first started. I hope something here helps:1. Make sure the cut edge is free of saw nicks, burrs, and file marks. There should be no edge imperfections that could initiate a crack.2. The cut edge should be flat. After any cutting or de-burr filing turn the edge on emery cloth placed on a flat surface. Removing material this way

eliminates high spots on the edge and ensures the edge has a full wall stock thickness.(see the first photo below)3. When the flare is started make sure the edge is not too wide.4. When rocking the bottle on the wood to roll the edge, do it gradually and evenly. It will take a number of turns. Periodically stop and examine the edgto make sure it is rolling evenly. Adjust downward pressure accordingly.5. Make sure the bottle stays round while rocking the bottle do not apply so much downward force that the edge of the bottle takes on an extreme ovalshape. Stop occasionally and use the dowel or push bottle over the neck end of another bottle or use a PVC pipe connector (photo 2 below) to "stretchthe edge back into round.

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

TheLimbReaper says: Aug 21, 2010. 4:16 PM REPAh gee, looking at your pics. I guess I can't add much useful as I too figured out to use the PVC collars also. I can suggest to use the shortenedbottom of a "cottle" and a leather mallet to help form an "inside" rolled lip. This works especially well if the bottle bottom is streached first. Also somsingle use propane cylinders (Worthington brand) when cut open (extreme caution warning: Be certain cylinder is completely empty before cuttingopen) have a dished bottom wish is handy in forming an internal bead. The "forming" can bottom must have a small hole drilled in it to avoid avaccum. I hope that's helpful to somebody.

TheLimbReaper says: Aug 21, 2010. 3:52 PM REPI wouldn't get too excited about posting the "beer bottle" stove since most kiddies know what beer is. I do have to agree with the comments against using thcans as the primary cooking vessel as they certainly are lined (at least the soda cans). With that said; I have thrown caution to the wind and made a coffeepercolator from Bud bottles myself.

lostdragon says: Aug 2, 2010. 12:30 PM REPI wouldn't use one of these to cook anything in. They are usually lined with something that isn't made to be heated and you'll end up eating it. Somebody emailed Heineken in a different 'ible about making a cook pot out of their beer cans and they replied with as much. Be careful.

TANZMEISTER says: Aug 2, 2010. 2:33 PM REPThey're lined with plastic. Though any that will vaporize will burn off the first time you use it. And you don't eat the flames (I hope).

TANZMEISTER says: Jul 17, 2010. 8:52 AM REPusing another bottle as a pot is a neat concept. However, it seems that with the flames racing up the sides your losing at least half your heat to thesurrounding system rather then transfering it to your desired heat reservoir (your pot). If having better eff iciency is not an issue, then using the bottle as a pis great. If better efficiency is an issue, then I'd recommend a pot with a larger base, twice the diameter of the heat source is usually recommended for gascamp stoves. your pot design is still the best I've seen here on instructcables!

TANZMEISTER says: Aug 2, 2010. 2:32 PM REPfail! I ment to say stove design at the end there

survivalman says: Jun 25, 2010. 1:44 PM REPGreat ible
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17/19


ch5 says: Apr 21, 2010. 11:07 AM REPAwesome!I didn't think that putting such a neat finish on the borders could be done by hand without some kind of weird specific tool.I'm doing this to my alcohol stoves soon :)

Thanks a lot.

kimbe mtumbo says: Feb 27, 2010. 5:10 AM REPQuite cool. I wish I had a set of these.

junits15 says: Sep 17, 2009. 3:42 PM REPwhat brand of soda uses these?

smn368 says: Sep 21, 2009. 6:14 AM REPthere were a few limited edition mt dew and other pepsi products that were in the same bottles

junits15 says: Sep 21, 2009. 12:55 PM REPas soon as i read, "limited" i went, DARN

Father Christmas says: Dec 26, 2009. 2:50 PM REPThe "Venom" brand energy drink also uses these bottles.

Father Christmas says: Dec 27, 2009. 5:45 PM REPspeaking of the Venom brand, i bought two last night and remember mentioning them here. So, naturally, I followed this instructable lol

hpstoutharrow says: Dec 28, 2009. 10:51 AM REPNicely done! The Venom graphic looks great as a cup.

Father Christmas says: Dec 28, 2009. 10:56 AM REPI agree. I am contemplating buying the other flavours just for the purpose of a full set, to give as gifts to those certain people who areobsessed with energy drinks..

hpstoutharrow says: Dec 28, 2009. 5:55 PM REPI found some Mt. Dew aluminum bottles with Halloween designs this last October. How's this as an "eye for an eye". Though Ithink I like the Venom eye better.
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18/19


Father Christmas says: Dec 28, 2009. 6:39 PM REPha! Eye for an Eye! That was pure genius! I never woulda thought of that! :)

hpstoutharrow says: Sep 17, 2009. 3:57 PM REPI received comments there are bottles of Mountain Dew. I have not found them myself.

voltagedude says: Sep 25, 2009. 5:18 PM REPone of my friends had one il ask him!

junits15 says: Sep 17, 2009. 5:40 PM REPok, I have sen bottle like this with coke in them, but they are a diffrent shape.

msw100 says: Nov 19, 2009. 1:43 PM REPGreat job, you must have had plenty of practice to get to this standard

jdc187 says: Sep 26, 2009. 2:08 AM REPwhile I love the commitment to craftmanship couldn't you just sand the upper edge smooth and role once

shamanwhitewolf says: Sep 25, 2009. 9:24 AM REP(Along the same lines: I am pretty sure not everyone who has built a bar-b-que from a steel barrel personally bought, and consumed the 50 gallons of CrudOil inside to get to an empty drum.)

Hehe You don't know my uncle down in S.E. Texas!

This is really cool. This was part of this week's email and the timing is perfect- it helps with some ideas for something I'm looking for. As a biker, I find it apain in the butt to fill the tank. The McCuff is a rubber-like device that makes it super easy, but you have to put it on, take it, etc. (I'm lazy, I know) So I'mthinking of trying to build something out of aluminum or stainless that stays in the take-fill hole and is collapsible. Basically, you'd open the fill hatch, lift themulti-section device with a twist (which locks it in the 'up' position, fill the tank, and collapse the device back down with a reverse-twist, close the hatch andgo. Any ideas how to add your brilliance to my idea and make it, you know, actually work?

dpainter says: Sep 24, 2009. 12:53 PM REPIs the end of the dowel, the end in the can, cut square or rounded?

hpstoutharrow says: Sep 24, 2009. 2:49 PM REPIt is square cut. But, there is really nothing particularly critical about the dowel or its dimensions. The point is just to use something with a friendly surfacto start the flare. A small diameter PVC pipe might also work. I just wouldn't use anything harsh like a steel pipe. Also something with a smalldiameter,like a pencil, might cause a crease in the flare edge given the small surface area, point contact.

soundmotor says: Sep 22, 2009. 5:57 AM REPNicely done! Have you had any problems with cracking or splitting when you did this?

hpstoutharrow says: Sep 22, 2009. 6:55 PM REPNo, not at all. The aluminum on the bottles is thick enough that it stretches well. I had the same concern. The first one I did (the blue bottle) I tried toanneal it with a torch after the first roll (It yellowed the lacquer). On the next ones I double rolled them without annealing it and there was no problem.

soundmotor says: Sep 23, 2009. 6:36 AM REP

I need to go hunt down some alu bottles. This project is just too cool! Kudos!

Kryptonite says: Sep 17, 2009. 3:37 AM REPI like the "please recycle" on the blue can! It just adds its own little touch, intended or not.

hpstoutharrow says: Sep 17, 2009. 4:05 PM REPMy goal was to downplay an alcohol brand name. So where possible I photographed the back of the bottles. So, highlighting the recycle symbol wasunintentional but, now that you mention it is rather appropriate. Good catch.
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19/19

cokecola says: Sep 17, 2009. 1:59 AM REPThis was very cool. I have been wondering how to make a rolled back edge like that. I was quite impressed!

ToniRose says: Sep 16, 2009. 9:23 PM REPVery cool. Are these bottles used in Europe and Asia? (Looks like the kind of hip design that wanders to the US late.) We could start a Hip Bottle Swap fordifferent languages, graphics and obscure names. I want one with Cyrillic characters!

piperjon says: Sep 16, 2009. 8:17 PM REPGreat follow up to the stove! I've searched my local area (Little Rock, Arkansas) and thus far haven't been able to come up with aluminum bottles yet. Butgiven time, I'm sure we will. Keep up the great work!

pineapplenewton says: Sep 16, 2009. 8:05 PM REPalso that is a very poor flame pattern on that pot waist alot of the flame

pineapplenewton says: Sep 16, 2009. 7:59 PM REPa bit tall don't you think?

Project_Nightmare says: Sep 14, 2009. 8:30 PM REPWow I think I'm in love with this guy's instructables and I cant even drink yet. (I only had small tastes and my parents always where watching.) Greatinstructables that I want to make, now I just need to get my parents to buy and drink all the beer...

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