Making you Own Billycans

Discussion in 'Self-made Gear' started by warthog1981, Jul 29, 2011.

  1. warthog1981

    warthog1981 Tracker

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    I thought Id do a post on how I make up my Billys
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    Take your tin and tie a peice of string around it and knot it.
    Then slide it off the tin and fold in half at the knot mark with a pen the middle.
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    Slide it back on to your tin this gives you the tins polar oposits on the rim mark the tin with marker.
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    Here is a side View of my D rings that I like to fit you can see there a loose fit
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    I set mine with a scrap bit of metal and a mallet they now look like this
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    Line them up on the side of your tin and mark where the holes need to be drilled
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    I use a center punch and a small hammer to start where the holes are to go.
    I put a peice ot timber in my vice and use that to support the tin while I center punch it.
    I use a little pillar drill and a new drill bit to drill my holes. A good tip is to put your pots lid back on when drilling as it helps to stop the pot flexing.
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    I like to drill my holes so there a tight fit for the little stainless steel bolts that I use .
    I need to screw them in , I only ever drill one hole at a time and the double check that the other hole in the D ring lines up with the mark. if not just rehammer the centerpunch mark.
    You end up with this
    [​IMG]
    Cut the bolts down and leave a few mm proud I now pean the ends of the bolts with a ball pean hammer I slide the tin onto the horn of my anvil. It can be done with a peice of timber supporting the inside of the pot and the hammer.
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    Now you will need some electrical conectors I got mine in Asdas bargan 75p for a stip on them enough to do half a dozen handles. And some steel cable this cable is stainless steel and a good bit thicker that bycical brake cable that ive use in the past.
    It came of some maker Bouys that ripped free in the last floods we had.
    It wreaked the clips that hold them in place so the were free to recycle :)
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    ones cut open they give you the clamps I just use a stanly knife :)
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    Cut your cable to lenght with a sharp pair of snips and thread through the D rings and tighten up with a Screw driver and a pair of pliers.
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    Take a scrap of paper and draw around your lid
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    Fold your circle in half then half again so its a quarter now open it up again and place on top of your lid.
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    I like my lid D Ring to be just off center the fold in the paper make it easy to line it up nice and central to the middle :) Drill and fit your D ring to the lid.
    I use a large blolt held in the vice to support the inside of the bolts to allow me to pean them the big bolt supports them one at a time :)
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    All peind
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    It does very little damage to the inside of the bolts so you dont end up with sharp edges in side your pot :)
    [​IMG]
    After that you should end up with something that should look like this
    [​IMG]
    The small one will boil about 600 ml annd the large one just over 1100ml :)

    Any Questions ?

    Russ
     
  2. madmax

    madmax Bushmaster

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    Looks good! Thanks for the pics and lesson.
     
  3. carnivor way

    carnivor way Scout

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    thats fn cool ! what kind of tins are you using . excellent post thank you for sharing .
     
  4. warthog1981

    warthog1981 Tracker

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    There just stainless steel storage tins form the local supermarket :)

    Thanks Russ
     
  5. Keithcompton

    Keithcompton Tracker

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    This is the kind of detailed, illustrated, useful post that keeps me coming back here. What are those pots/tins? They look like old fashioned coffee or sugar tins. Thanks!
     
  6. carnivor way

    carnivor way Scout

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    thanks worthog i hadnt noticed them around here, but i will keep an eye out for them . thats a brilliant idea thanks again,
     
  7. Thunder 9

    Thunder 9 Guide

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    Thanks warthog1981 for an
    excellent photo tutorial.

    Beautiful customization.

    Now if someone would tell
    me the American name for
    those electrical connectors
    and where to get them
    I would be in business.

    Tried to find some at Ace Hardware
    when I modded a Zebra pot
    and they could not find them
    from my verbal description.
     
  8. tonyclark

    tonyclark Scout

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    Thank you, Sir. Hope you get much use with them.:4:
     
  9. wildernesswikiup14

    wildernesswikiup14 Guide Bushclass I

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    that's really neat. I'm saving this thread and trying that myself. thanks =)
     
  10. Eric_Methven

    Eric_Methven Scout

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    THIS is what you want. It's called a wire connector terminal block strip.

    Eric

     
  11. nattilee

    nattilee Tracker

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    Very nice!
    Thank you for the details!
     
  12. OddTheViking

    OddTheViking Guide

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    Nice instructions and photos, thanks!

    The only thing missing is folding side handles, and I know I have seen a thread here on adding them. I think that thread used pop rivets, but I suppose the same mechanism for attaching the bail handle could be used, provided something was done to prevent leaking. Perhaps one could solder or braise the inside around the screw head?
     
  13. Easy_rider75

    Easy_rider75 Bushwhacker

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    Really nice idea. Think I need to make a Wally World run next week after payday :D thanks for the detailed pics.
     
  14. nickosnow

    nickosnow Guide

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    Well done! I'll be taking lesson learned here for future project, thanks!
     
  15. Teno

    Teno Scout

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    Yes, would you make me one ??? :4::4::4:

    Good work, you inspire me!

    Marcelo from Argentina
     
  16. Wildwood Wanderer

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    thats cool, thanks for the tutorial
     
  17. Trekon86

    Trekon86 Guest

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    Most excellent, dude!
    :)

    PMZ
     
  18. Nohbody

    Nohbody Tinder Gatherer

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    At BOSS I think we just used folger's coffee cans with holes punches in the top and a wire run through. It was difficult to tell, because they were completely charred black. They worked pretty well, except sometimes the lentil stew came out purple.

    Sometimes it's better not to think too hard about it.
     
  19. warthog1981

    warthog1981 Tracker

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  20. mainewoods

    mainewoods Maine Supporter Supporter Bushclass I

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    Outstanding Warthog Thanks for sharing! May have to add this to My Make list. Do one add two LOL. Great Post
     
  21. Canadian Woodsman

    Canadian Woodsman Scout

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    Excellent work! I like the simplicity of the peined bolts, very nice!
     
  22. Teno

    Teno Scout

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  23. jss4fish

    jss4fish Tracker

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    Very nice! With how hard it is to find Zebra cans and the price point it is always nice to find a good alternative.
     
  24. MiddleWolf

    MiddleWolf Guide

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    Do a print screen of the page and go to your local electrical supply house or Google "electrical connecters" and compare pictures.
     
  25. bluedog

    bluedog Scout

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    Nice work, but you don't need to use steel cable and connectors to have a close stowing handle.
    Solid wire, formed into an ellipse, will fold down around the can, touching all the way around so it almost isn't there at all. You already have clearance for it with the way your ears are bent out from the sides.
    Mine was made on a small 100mm diameter stainless mug, with the handle removed to turn it into a billy. Fits inside a hobo stove made from a 120mm Zebra can.
     

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  26. Survive

    Survive Scout

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    great work!
     
  27. CharlieTN

    CharlieTN Tracker

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    Great tutorial.

    I made one and used similar d-rings but attached them with JBweld. So far it's held up great.

    Love making and using my own gear. Gives me even more satisfaction as well as I can build more for the same amount of money as I can buy it.

    Charlie
     
  28. Dadio

    Dadio Supporter Supporter Bushcraft Friend Bushclass I

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    Beautiful work, and great tips!
     
  29. Prof

    Prof Guide Bushclass II

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    This is an excellent step-by-step explanation with very clear photos!

    Thanks for the clever, yet simple, way to determine when the handles are exactly opposite each other; I had often resorted to more complicated measuring techniques.
     
  30. warthog1981

    warthog1981 Tracker

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    Thanks Folks :) im glad that its been of some use :)
     
  31. Survivor Johnny

    Survivor Johnny Scout

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    Just so you can see your still inspiring new home made Billies. Thanks for the tips

    image.jpg
     
  32. wingnuts

    wingnuts Guide

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    Nice work!! I really like your trick of gutting terminal blocks for use as cable crimps!!! Good onya and thanks for the post!
     
  33. kreate

    kreate Scout

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    Man, this is an awesome post! Now I'm off to the store to find some steel storage containers :dblthumb:
    Thanks,
    -Kreate
     

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