Boy Scout Merit Badge
- Read the safety rules listed in the Metalwork merit badge pamphlet.
Describe to your counselor how to be safe while working with metal. Because
this merit badge offers four options, show your counselor which additional
safety rules apply to the discipline you choose and discuss them with your
- Do the following:
- Define the term native metal.
- Define the term malleable.
- Define the term metallurgy.
- Define the term alloy.
- Name two nonferrous alloys used by pre-Iron Age metalworkers, and
name the metals that are combined to form these alloys.
- Explain the term ferrous, and name three ferrous alloys used by
modern metal workers.
- Describe how to work-harden a metal.
- Describe how to anneal a nonferrous and a ferrous metal.
- Do the following:
- Put a 45-degree bend in a small piece of 26- or 28-gauge sheet
brass or sheet copper. Note the amount of effort that is required to
overcome the yield point in this unworked piece of metal.
- Work-harden another piece of the same sheet brass or sheet
copper, and then put a 45-degree bend in it. Note the amount of effort that
is required to overcome the yield point.
- Soften the same bent, work-hardened piece by annealing it, and
then try to remove the 45-degree bend. Note the amount of effort that is
required to overcome the yield point.
- Join two small pieces of scrap metal using a hammered rivet.
Repeat the process using a pop rivet.
- Using a flatlock seam, join two pieces of scrap metal together
with either lead-free solder or silver solder.
- Make a temper color index from a flat piece of steel. Using hand
tools, make and temper a center punch of medium-carbon or high-carbon steel.
- Using metal cans, practice using the basic metalworking tools and
techniques by making at least two tasteful objects that require cutting,
bending, and edging.
- Do ONE of the following:
- Visit an experienced sheet metal mechanic, tinsmith, coppersmith,
silversmith, jeweler, founder, or a blacksmith at his or her workshop. You
may select a skilled hobbyist or a professional. Ask permission to see the
tools used and to examine examples of the work made at the shop. Inquire
about the level of education required to become an apprentice craftsman.
- If you have (or your counselor has) access to the Internet,
explore metalworking occupations by conducting a Web search. With your
counselor's help and guidance, find at least five metalworking-related Web
sites. Print a copy of the Web pages and discuss them with your
When conducting your Web search, use keywords such as
metallurgy, metalwork, spinning metal, metal fabrication, steel
fabrication, aluminum fabrication, casting metal, pattern making, welding,
forge welding, blacksmith, art metal, Artist Blacksmith Association of North
America, farrier, brazing, goldsmith, machinist, or sheet metal
- After completing the first three requirements, complete at least ONE of
the options listed below.
- Option 1--Sheet Metal Mechanic/Tinsmith
- Name and describe the use of the basic sheet metalworking tools.
- Create a reasonably accurate sketch of two tasteful objects to make
from sheet metal. Include each component's dimensions on your sketch.
- Using patterns provided either by your counselor or made by you, make
at least two tasteful objects out of 24- or 26-gauge sheet metal. Use a
metal that is appropriate to the object's ultimate purpose.
- Both objects must be constructed using cutting, bending, edging, and
either soldering or brazing.
- One object also must include at least one riveted component.
- If you do not make your objects from zinc-plated sheet steel or
tin-plated sheet steel, preserve your work from oxidation.
- Option 2--Silversmith
- Name and describe the use of the basic tools used by a silversmith.
- Create a reasonably accurate hand-drawn sketch of two tasteful objects
to make from sheet silver. Include each component's dimensions on your
- Using patterns either provided by your counselor or made by you, make
at least two tasteful objects using 18- or 20-gauge sheet copper. If you
already have prior silversmithing experience, you may substitute sterling
silver, nickel silver, or lead-free pewter.
- At least one object must include a sawed component you have made
- At least one object must include a sunken part you have made
- Both objects must include a soldered joint.
- Clean and polish your objects.
- Option 3--Founder
- Name and describe the use of the basic parts of a two-piece mold. Name
at least three different types of molds.
- Create a reasonably accurate sketch of two tasteful objects to cast in
metal. Include the height, width and length on the sketch.
- Do the following:
- Using a pattern provided by your counselor and another one you have
made yourself, make two molds. Position the pouring gate and vents
yourself. Do not use copyrighted materials as patterns.
- Make a casting using a mold provided by your counselor and
make a casting using the mold that you have made. Use lead-free pewter
when casting each mold.
- Remove all evidence of gates, vents, and parting-line flash from
- Option 4--Blacksmith
- Name and tell the use of the basic tools used by a blacksmith.
- Make a reasonably accurate sketch of two tasteful objects to
hot-forge. Include each component's dimensions on your sketch.
- Using low-carbon steel at least ¼-inch thick, perform the following
- Draw out by forging a taper.
- Use the horn of the anvil by forging a U-shaped bend.
- Twist steel by placing a decorative twist in a piece of square
- Use the edge of the anvil to bend metal by forging an L-shaped bend.
- Using low-carbon steel at least ¼-inch thick, make at least two
tasteful objects that require hot-forging.
- Include a decorative twist on one object.
- Include a hammer-riveted joint in one object.
- Preserve your work from oxidation.
BSA Advancement ID#: 74
Source: Boy Scout
Requirements, #33215E, revised 2002