2. For this project I wanted to recreate my grandfather’s old Zippo lighter from 1941. I ordered
one online from Zippo but it still hasn’t arrived. In the meantime I had picked up a similar
model made by Ranson and decorated it the way he use to with a penny ,carved initials, and a
date. The lighter itself is small enough to fit in the palm of your hand.
3. First I took measurements, made sketches, and figured out the math to resize the piece.
4. After I had my measurements I cut and assembled the lighter. Unfortunately The edges
weren’t as clean as I would have liked (too much glue maybe?). I used one continuous
piece of cardboard for the body, measuring and then scoring the inside to get the correct
shape.
5. Looking down into the piece from the left you have the button that ignites the
flame, the area where the flame comes out, and the lid that opens and closes. To make
the hinge for the lid I compressed two pieces of cardboard and attached it to the inner
body of the lighter itself. I scored the hinge through one layer of cardboard to allow it to
bend but retain its strength. I then peeled back a section of the inside of the lid so it
would sit flush.
6. I created a spring to allow the igniter button to compress by cutting two rubber bands and
duct taping them to the underside of the lighter top. This allows the button to compress
without getting stuck.
8. I wanted to add the same special marks to the piece that were my initial inspiration for
the project so I carved into the cardboard my grandfathers initial's and hand cut a
stencil of a penny onto brown colored paper.
9. In the end I would have liked the the lines to have been cleaner but due to the handling of
the cardboard it began to weaken in some areas as seen above. I cut away the cardboard
ply to create the seamless look but too much glue may have ruined that. All in all it was an
interesting project which gave me ideas for my personal work.
