Polished Aluminum Bauble Ornaments From Tin Foil

As I was thinking about what to make the Things for their ornaments this year, I thought this might be a new fun technique to try. And pretty easy to turn into ornaments. I also thought the shiny polished Aluminum would have a nice retro mercury-glass look...which it did, kinda sorta, and they looked awesome on the Christmas tree.

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'Japanese polished Aluminum foil balls' have been popping up all over the place out there - these balls are made from nothing more than a roll of tin foil, balled up and compacted by hammering, then sanded and polished to a beautiful shine. That, and many hours of love. There are plenty of videos on YouTube showing the process of making polished Aluminum balls, also credit to this Instructable: https://www.instructables.com/id/How-to-Make-a-Pol... which got me started on the process of making the ornaments.

As I was researching, I didn't find all answers to my questions out there on the interwebs, so hopefully mine will answer some additional questions for others in the community (like size of finished balls, techniques for minimizing creases, etc.)

So my first question was: How much foil will I need to make an ornament ball, say, 3 inches in diameter?

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I couldn't seem to find an answer, and everyone was using different foils of different sizes and thicknesses, so I just bought a roll of Reynolds Wrap (200 Sq ft size, or 66.67 yards x 12"), fairly commonly available across the US, and used the whole roll of foil to find out for myself. The resulting ball was way too big for a tree ornament, about 5.5" diameter and heavy (850g/1lb 14 oz!). So I decided to go for half the roll of foil for each of the ornament balls. These turned out to be just over 3.5" diameter...still slightly larger than I'd wanted but good enough as I didn't want to make any more at this point!

They were not too heavy (at ~14oz, still the heaviest ornaments on the tree), so did need to be hung on lower branches of the tree. Slightly smaller balls would have been ideal (my suggestion for others is to use a roll of the Reynolds 75 sq ft foil per ball, which should be perfect).

The larger ball didn't go to waste btw - it was turned into a giant ornament and hung in the dining room window, using 20lb fishing line.

Supplies Needed

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• Aluminum Foil (I used this Reynolds Wrap: https://tinyurl.com/y8uoeerc)
• Sandpaper (multiple grits, about 120 to grit. I got these: https://tinyurl.com/y6w3pmw9)
• Aluminum polish (https://tinyurl.com/ya7ozdpx)
• Cloths for polishing (I used cut up old white T shirts)
• Eye hooks (I used 1 3/16" 210 hooks: https://tinyurl.com/yct8w7y8)
• End caps from cigar tubes
• Fishing line (12lb or higher)