Make Your Own Copper Bopper Billet

Making your own copper billet is easy. Go to a plumbing supply house, Lowe's, Home Depot, etc., and purchase some copper end caps in whatever size you want. I find that 3/4" and 1" are the best all around sizes to use. These work well for general thinning and also for closer finish work. Be sure to tell the clerk at the store what you are using them for, just to completely confuse his or her day. After selecting your copper end cap, get a medium to large ball-peen hammer and place it in a vice with the ball end up. Place the copper cap on the ball and start shaping it with another hammer. You have to keep rotating the cap to get a nice rounded appearance. I think that this also hardens the copper a little. Once you have the cap rounded over to your satisfaction, you are ready to fill it with lead and attach it to a handle.
First, I select a piece of hardwood dowel that fits inside the cap rather tightly. I find that 4" is about right but some people like a longer handle. I then drill a hole about 1/2" deep in the dowel to accept more lead.
At this stage, you can either melt some wheel weights with a torch (preferred), and pour some of the lead in thd dowel hole and some in the cap itself (be sure to leave enough room in the cap for secure gluing), or you can simply fill the hole and cap with lead shot. This method is for those who don't have a torch, are afraid of fire, or can't get wheel weights. I find that it's not quite as solid, either, but certainly works well enough.
To attach the cap to the dowel, I use two part 5 minute epoxy glue. This stuff is really strong and should hold up well if you left enough gluing area.
Take a few minutes to round over the end of your bopper. It makes holding it so much more comfortable. I also wrap several layers of athletic tape around mine for additional comfort. Some people use soft leather.
Now that you have made a great billet for next to nothing, go get a few nice spalls and BUST UP some rocks!!!!

Back to Tim's Flintknapping Page