im thinking of making a figure from scratch with metal
how sould i go about doing it
what tools should i use to do it
what paint works best
and more important what metal should i use

oh and by the way this will be my first custom
when its done

anyone have any suggestions?

I work with metal for my job except I have access to machines that make things easier.

What I would advise for doing it yourself is:

Get all your designs finalised
Make mock ups using card/paper, then at least you can see what it might turn out like.
Use Aluminium (aluminum to USA folk) if you can get it, as it is soft and easy to shape and cut. If this proves
expensive to buy 1.2mm mild steel is ok to work with by hand but harder to cut.

Tools you can use: Jigsaws or junior hacksaw for cutting, a vice, hammer and some grips for folding/shaping
If you know anyone who can weld it may be useful, not only for piecing together but for filling in gaps
and smoothing areas by grinding the welds.

Use metal primer and car spray paint on metal parts.

This is just a rough guide, I am sure there are people on here who know more about specific areas.

Good luck.

For simple construction, I'd say go with aluminum flashing, as you can cut it with even a pair of scissors and you can get it in large rolls. Attach it with rivets or epoxy. Keep in mind that welding aluminum is more toxic than steel, and harder to do.

Mild steel is harder to cut and fold by hand - you'll want a mechanical shear of some sort (or a good hacksaw and many blades) and possibly an oxy-acetelyne welding setup (IMO, arc methods are overkill on thinner gauges). It also rusts.

It may be helpful to learn how to at least braze metal. It's not too hard. You'll definitely need some sanding equipment - a rotary tool might do the job depending on the metal you use, or an angle grinder, or just many grades of good old sand paper and elbow grease. Also, vises and angle clamps. Punches if you're going to be using rivets. A drill with various bits...

Make an accurate prototype out of cardboard, foamcore, styrene, whatever you want. It'll make your life a whole lot easier.

Trust you me, it takes a lot of work to make a non-posable humanoid form out of metal (I'm an artist working in steel), but it can be done.


Alternatively, you can model your parts and cast them in various light metals. Relatively less work, but probably just as costly in the end.

No advice, but a Question:


What the hell are you making? A metal sonic? 'Cuz that would be kickass in so many ways.

You need to PM Wikkid...he has done a lot of work with metal in the past.

Or Don Figuroa ;)

Or you can just check out Don's metal customs if you have not seen them yet. They are a sight to behold. ... and BIG!

Heh, I was thinking about that as I posted, but I didn't know how many people knew about his kitbashes.