Metalwork Merit Badge

Free Resources and Answers

Time: 2–4 weeks
Difficulty: Moderate
Setting: Workshop, forge
Best For: Scouts interested in tools, crafting, building
Hands-On Level: High
Eagle Required: No

The Metalwork merit badge gives you a chance to turn a piece of metal into something useful or decorative. You will learn how to shape, cut, bend, and join metal while using the right tools and safety practices. Each project helps you build skill, control, and confidence.

As you work, you will need to plan each step before you begin. You will choose materials, follow a design, solve problems, and make changes when something does not work as expected. These skills can help you with many other projects, both in Scouting and in everyday life.

Metalworking can become a hobby, a career, or simply a skill you are glad to have. This badge introduces you to several metalworking methods and shows you the care needed to create a finished piece. When your project is complete, you will have something you made with your own hands.

The requirements for this merit badge were updated effective January 1, 2025.

Download the Metalwork Merit Badge Requirements

Metalwork Merit Badge Pamphlet

Metalwork Merit Badge Printable Requirement Check Off Sheet

Checklist for All Merit Badges

Help with Answers for Merit Badge Requirements

Find specific helps for some of the Metalwork merit badge requirements listed below. Some of these resources will just give the answers. Others will provide engaging ways for older Scouts to introduce these concepts to new Scouts.

• Requirement 1: Safety
• Requirement 2: Terms
• Requirement 3: Methods
• Requirement 4: Careers
• Requirement 5 Option A: Sheet Metal Mechanic/Tinsmith
• Requirement 2 Option B: Silversmith
• Requirement 5 Option C: Founder
• Requirement 5 Option D: Blacksmith
• More Resources

Requirement 1: Metalwork Safety

What You Need To Do

Read the safety rules for metalwork and discuss them with your counselor. Include the extra safety rules for the metalwork option you plan to complete in Requirement 5.

Helpful Tips

• Wear safety glasses whenever metal pieces, sparks, or dust may fly.
• Use hearing protection around loud tools such as grinders and power hammers.
• Wear closed-toe shoes and clothing made from natural fibers.
• Tie back long hair and remove loose jewelry before using tools.
• Keep the work area clean, dry, and free of clutter.
• Check each tool for damage before using it.
• Use each tool only for its proper job.
• Clamp metal in place before cutting, drilling, or filing it.
• Treat recently heated metal as hot, even when it does not glow.
• Keep flammable materials away from sparks, flames, and hot metal.
• Find the fire extinguisher, first-aid kit, and emergency exits before starting.
• Review the special safety rules for sheet metal, blacksmithing, foundry work, or silversmithing with your counselor.

Resources

• Metalwork Tools Workshop Safety Training (video)

Leader Tips

• Walk through the work area with the Scout before any tools are used.
• Show safe tool use, then let the Scout practice under close supervision.
• Match safety instruction to the option the Scout selects for Requirement 5.
• Stop the activity when unsafe clothing, damaged tools, or poor work habits create a risk.

Requirement 2: Metalworking Terms

What You Need To Do

Define six common metalworking terms. Use clear definitions and be ready to discuss each term with your counselor.

Helpful Tips

• Native metal occurs naturally in a nearly pure form.
• Copper, gold, silver, and tin can occur as native metals.
• Malleable metal can be hammered, pressed, or rolled into a new shape without breaking.
• Metallurgy is the study and practice of producing, shaping, and treating metals.
• An alloy is a mixture of a metal with one or more other elements.
• Alloys can be harder, stronger, or more resistant to corrosion than pure metals.
• Nonferrous metals contain no iron or only a very small amount of iron.
• Copper, aluminum, silver, and gold are nonferrous metals.
• Ferrous metals contain iron.
• Carbon steel, stainless steel, and cast iron are ferrous metals.
• Some ferrous metals rust when exposed to water and oxygen.
• Stainless steel resists rust because it contains chromium.

Resources

• Metallurgy: From Rocks to Alloys (video)

Leader Tips

• Ask the Scout to define each term in their own words.
• Place several metal samples on a table when possible.
• Help the Scout connect each term to a tool, object, or project.
• Correct definitions without requiring a memorized speech.

Requirement 2a: Early Nonferrous Alloys

What You Need To Do

Name two nonferrous alloys used before the Iron Age. Name the metals combined to make each alloy.

Helpful Tips

• Bronze is a nonferrous alloy made mainly from copper and tin.
• Bronze is harder than pure copper.
• Early metalworkers used bronze for tools, weapons, containers, and decorations.
• Electrum is a nonferrous alloy made mainly from gold and silver.
• Electrum can occur naturally or be made by mixing the metals.
• Early metalworkers used electrum for jewelry, coins, and decorated objects.
• Neither bronze nor electrum contains iron as a main ingredient.
• Bronze and electrum meet the requirement as two separate alloys.
• Name both the alloy and its main metals during the counselor discussion.

Resources

• How Alloys Made the Bronze Age Possible. Forging a New Era (video)
• From Gold and Silver to Electrum: The Truth About This Rare Alloy (video)

Leader Tips

• Provide pictures or samples of bronze and electrum when available.
• Ask the Scout to match each alloy with its main metals.
• Keep the discussion focused on alloys used before the Iron Age.
• Accept clear answers given in the Scout’s own words.

Requirement 2b: Modern Ferrous Alloys

What You Need To Do

Name three iron-based alloys used by modern metalworkers. Give a simple description of each one.

Helpful Tips

• Carbon steel is made mainly from iron and carbon.
• Carbon steel is used for tools, machines, buildings, and vehicle parts.
• Stainless steel contains iron, carbon, and at least about 10.5 percent chromium.
• Chromium helps stainless steel resist rust and corrosion.
• Stainless steel is used for sinks, cookware, medical tools, and outdoor equipment.
• Cast iron contains iron and a higher amount of carbon than most steel.
• Cast iron is hard but can crack under a sharp blow.
• Cast iron is used for cookware, pipes, machine bases, and engine parts.
• Carbon steel, stainless steel, and cast iron are three suitable answers.
• Tool steel and alloy steel are other modern ferrous alloys.

Resources

• What Are the Different Types of Steel? (video)

Leader Tips

• Show the Scout common objects made from different ferrous alloys.
• Ask why each alloy fits its intended use.
• Help the Scout compare hardness, strength, and resistance to rust.
• Avoid requiring detailed chemical formulas.

Requirement 2c: Work-Hardening Metal

What You Need To Do

Describe how repeated shaping makes some metals harder and less flexible. Include common ways metal can be work-hardened.

Helpful Tips

• Work-hardening occurs when metal is bent, hammered, rolled, drawn, or pressed.
• The shaping takes place while the metal is below its normal heat-treating temperature.
• Each change in shape makes further movement inside the metal more difficult.
• The metal becomes harder and stronger.
• The metal also becomes less flexible.
• Copper, brass, aluminum, and some steels can be work-hardened.
• Hammering the bend in a copper or brass sheet hardens the worked area.
• Continued working can make the metal brittle.
• Cracks may form when the metal is worked too much.
• Annealing can soften work-hardened metal before more shaping.

Resources

• Work Hardening and Annealing (video)
• Self Organising Steel Balls Explain Metal Heat Treatment (video)

Leader Tips

• Use a soft metal sample for a simple demonstration.
• Let the Scout compare worked and unworked parts of the sample.
• Ask the Scout to describe changes in stiffness and flexibility.
• Keep fingers clear of hammers, rollers, and sharp edges.

Requirement 2d: Annealing Metal

What You Need To Do

Describe how annealing softens nonferrous and ferrous metals. Include the main heating and cooling difference between the two types.

Helpful Tips

• Annealing uses controlled heating and cooling to soften metal.
• Annealing can remove hardness caused by hammering, bending, or rolling.
• Copper and many copper alloys are heated evenly to a dull red color.
• These nonferrous metals may then be cooled in air or quenched in water.
• Quenching copper does not harden it as quenching high-carbon steel can.
• Ferrous metal must be heated to the correct temperature for its type.
• Annealed steel is usually cooled very slowly.
• Steel may cool inside a shut-off furnace or in an insulating material.
• Slow cooling gives the steel time to soften.
• Heating temperatures vary by alloy, size, and intended result.
• A counselor or trained metalworker should supervise all annealing work.
• Hot metal may look the same as cold metal, so use proper tools to handle it.

Resources

• Annealing Stainless Steel Spoons (video)
• Introduction to Annealing (video)
• How to Anneal Silver, Copper and Other Nonferrous Metals (video)

Leader Tips

• Demonstrate annealing only in a workspace made for hot-metal work.
• Compare the cooling method used for copper with the slow cooling used for steel.
• Have the Scout describe the process before handling any heated metal.
• Provide close supervision, protective equipment, and proper ventilation.

Requirement 3a: Work-Harden Sheet Metal

What You Need To Do

Put a 45-degree bend in 26- or 28-gauge sheet brass or copper. Heavily peen along the bend, and compare the force needed to bend the metal before and after work-hardening.

Helpful Tips

• Wear safety glasses and follow your counselor’s safety directions.
• Smooth or cover sharp sheet-metal edges before handling the piece.
• Mark a straight bend line on the metal.
• Use a vise, bending brake, or other approved tool to make a 45-degree bend.
• The yield point is reached when the metal begins to hold its new shape instead of springing back.
• Pay attention to the force needed to pass the yield point during the first bend.
• Place the metal on a firm steel surface before peening.
• Peening means striking the metal many times with the rounded end of a ball-peen hammer.
• Use controlled blows along the full bend line.
• Heavy peening changes the shape of the metal and makes the worked area harder.
• The hardened bend should resist further bending more than the unworked metal.
• Record the difference in force using simple terms such as light, moderate, or heavy.

Resources

• Work Hardening of Copper (video)

Leader Tips

• Prepare the sheet metal so Scouts do not handle rough or burred edges.
• Demonstrate a controlled hammer swing before the Scout begins.
• Ask the Scout to compare the metal before bending, after bending, and after peening.
• Keep hands and other Scouts outside the hammer’s striking area.

Requirement 3b: Anneal the Metal

What You Need To Do

Anneal the work-hardened piece from Requirement 3a. Try to remove the bend and compare the force needed with the force required before annealing.

Helpful Tips

• Annealing softens metal by heating it to the proper temperature.
• Complete this work only with your counselor or another trained adult.
• Place the metal on a fire-safe surface.
• Keep flammable materials away from the heating area.
• Use tongs or pliers made for handling hot metal.
• Heat the bend area evenly instead of holding the flame on one small spot.
• Follow your counselor’s directions for the proper heat level.
• Copper or brass may be cooled in air or quenched as directed by the counselor.
• Quenching means placing heated metal into a suitable cooling liquid.
• Never pick up heated metal with bare hands.
• Metal may remain hot even when it no longer glows.
• After the piece is cool, try to straighten the 45-degree bend.
• The annealed metal should require less force to pass the yield point.
• Compare the force needed before and after annealing.

Leader Tips

• Control the torch, fuel, ventilation, and cooling setup.
• Demonstrate safe heating and handling before the Scout begins.
• Ask the Scout to describe the change in stiffness after annealing.
• Keep a fire extinguisher and first-aid supplies nearby.

Requirement 3c: Temper Steel and Make a Center Punch

What You Need To Do

Make a temper color index from flat steel. Then use hand tools to shape, harden, and temper a center punch made from medium-carbon or high-carbon steel.

Helpful Tips

• A temper color index shows the surface colors produced as polished steel is heated.
• Clean and polish the flat steel so the colors are easy to see.
• Heat the steel slowly and evenly under close adult supervision.
• The colors usually move from pale yellow through brown, purple, and blue.
• The exact color and temperature can vary with the steel and surface condition.
• Label or record the color bands after the steel cools.
• Use medium-carbon or high-carbon steel for the center punch.
• Shape the punch with hand tools such as a hacksaw and files.
• Form a strong point with the angle recommended by your counselor.
• Smooth sharp corners and rough file marks.
• Hardening requires heating the working end and cooling it in the proper medium.
• The correct heating temperature and cooling medium depend on the steel.
• Follow the steel supplier’s directions or the counselor’s approved procedure.
• Harden only the working end of the punch.
• Clean the surface after hardening so temper colors can be seen.
• Reheat the punch slowly until the chosen temper color reaches the point.
• Cool the punch as directed to stop the tempering process.
• A properly tempered punch has a hard point with less risk of cracking.
• Wear eye protection when testing the finished punch.

Resources

• How to Forge a Center Punch (video)

Leader Tips

• Confirm the type of steel before choosing a heat-treatment method.
• Guide the Scout through each step instead of completing the tool for them.
• Control all heating, quenching, and testing areas.
• Check the finished punch for cracks or damage before it is used.

Requirement 4a: Explore a Metalworking Career

What You Need To Do

Name three careers that use metalworking skills. Choose one career and research the preparation, costs, job outlook, pay, advancement opportunities, and possible career goals.

Helpful Tips

• Start by listing three careers that interest you.
• Pick one career for deeper research.
• Find the education needed to enter the field.
• Check whether the career requires an apprenticeship, license, or certification.
• Research the tools, classes, fees, and other starting expenses.
• Find the experience employers expect from new workers.
• Look for the current starting salary in your area.
• Check whether jobs are expected to increase, decrease, or remain steady.
• Find possible promotions or advanced jobs in the field.
• Write down short-term and long-term career goals.
• Use reliable sources such as trade groups, schools, unions, employers, or government career websites.
• Discuss your research and your interest in the career with your counselor.

Metalworking Careers

• Blacksmith
• Welder
• Metal fabricator
• Machinist
• Sheet metal worker
• Jeweler or silversmith
• Tool and die maker
• Foundry worker
• Metallurgist
• Welding inspector
• Quality control inspector
• Pipefitter
• Metal sculptor
• Automotive technician
• Aircraft maintenance technician
• Metalworking instructor

Resources

• Sheet Metal Workers Careers (video)
• What Kinds of Careers Are in Metalcasting? (video)
• Blacksmithing 101: What is Blacksmithing? (video)
• Career Advice on Becoming a Silversmith (video)

Leader Tips

• Help the Scout choose three careers with clear links to metalworking.
• Guide the Scout toward reliable and current career information.
• Ask questions about training, costs, pay, and advancement.
• Let the Scout decide whether the career matches their interests and goals.

Requirement 4b: Explore a Metalworking Hobby

What You Need To Do

Choose a hobby that uses metalworking skills. Research the training, costs, groups, and goals connected with the hobby, then discuss your findings with your counselor.

Helpful Tips

• Choose a hobby that matches your interests and available workspace.
• Find the basic skills needed to begin safely.
• Look for classes offered by shops, clubs, schools, or community groups.
• Make a list of the tools and safety equipment required.
• Include the cost of metal and other project materials.
• Check whether tools can be borrowed or rented.
• Find a club, maker space, guild, or trade group connected with the hobby.
• Ask whether the group offers classes, mentors, demonstrations, or shared tools.
• Start with a small project that uses basic skills.
• Set a short-term goal that can be completed soon.
• Set a long-term goal that requires more practice or equipment.
• Discuss the costs, training, benefits, and goals with your counselor.

Metalworking Hobbies

• Blacksmithing
• Silversmithing
• Jewelry making
• Sheet metal projects
• Tinsmithing
• Metal sculpture
• Decorative copper work
• Tool making
• Metal casting
• Model engine building
• Metal engraving
• Repoussé and chasing
• Metal restoration
• Automotive restoration
• Welding art
• Building metal furniture

Resources

• Why Blacksmithing? (video)
• The Lost Art of Tinsmithing (video)
• Working with Silver is Awesome (video)

Leader Tips

• Help the Scout choose a hobby that can be practiced safely.
• Discuss workspace, supervision, tools, and costs before projects begin.
• Connect the Scout with a qualified instructor or local organization when possible.
• Encourage goals that build skills through safe, manageable projects.

Requirement 5A-1: Sheet Metalworking Tools

What You Need To Do

Name the basic tools used for sheet metalwork. Describe the job each tool performs.

Helpful Tips

• Tin snips cut thin sheet metal by hand.
• Straight-cut snips make straight cuts and gentle curves.
• Left-cut and right-cut aviation snips help cut tighter curves.
• A sheet metal shear makes long, straight cuts.
• A bending brake holds metal and makes straight, even bends.
• Hand seamers grip and bend small sections of sheet metal.
• A mallet shapes metal without leaving deep hammer marks.
• A ball-peen hammer shapes metal and sets some types of rivets.
• A metal file removes burrs and smooths sharp cut edges.
• A scratch awl marks lines and hole locations on metal.
• A steel rule measures straight lines and short distances.
• A square marks 90-degree lines and checks corners.
• A center punch makes a small dent before drilling a hole.
• A drill makes holes for rivets, fasteners, or fittings.
• A hand punch makes clean holes in thin sheet metal.
• A rivet setter or rivet tool fastens metal parts together.
• A soldering iron or torch heats a joint for soldering.
• Tongs and pliers hold small, sharp, or heated pieces.

Resources

• Essential Metal Fabrication Tools for Beginners: Tips and How I Use Them! (video)

Leader Tips

• Place the tools on a table and let the Scout identify each one.
• Demonstrate the safe grip and purpose of each tool.
• Compare tools with similar jobs, such as snips and shears.
• Keep damaged or unsuitable tools out of the work area.

Requirement 5A-2: Sketch Two Sheet Metal Projects

What You Need To Do

Draw two objects you plan to make from sheet metal. Show every part and include its dimensions, even though the drawings do not need to be to scale.

Helpful Tips

• Choose projects that can be made with 24- or 26-gauge sheet metal.
• Pick objects with a clear purpose, such as a tray, box, scoop, or tool holder.
• Draw the finished shape from more than one view when needed.
• A top, front, and side view can make the design easier to follow.
• Draw each separate component used in the project.
• Write the length and width beside each component.
• Include the height or depth of the finished object.
• Mark the location of every bend.
• Use solid lines for cuts and a different line style for bends.
• Include tabs, seams, folded edges, and overlapping joints.
• Mark the location and size of rivet holes.
• Show which joints will be soldered or brazed.
• Include extra metal needed for folded edges and seams.
• Check whether the parts will fit together before cutting metal.
• Ask your counselor to approve both designs and patterns before work begins.

Leader Tips

• Help the Scout choose projects that fit the available time and tools.
• Check the dimensions and joining methods before approving the design.
• Ask the Scout to describe the order of construction.
• Allow the Scout to revise the sketch when a part will not fit.

Requirement 5A-3: Make Two Sheet Metal Objects

What You Need To Do

Make two objects from 24- or 26-gauge sheet metal using approved patterns. Both objects must use cutting, bending, edging, and either soldering or brazing, and one must include a riveted component.

Helpful Tips

• Use a metal suited to the finished object’s purpose.
• Use zinc-plated steel, tin-plated steel, copper, brass, or another approved sheet metal.
• Follow a pattern supplied by your counselor or one your counselor approved.
• Transfer all cut lines, bend lines, and hole locations to the metal.
• Check every measurement before making a cut.
• Wear safety glasses and protect your hands from sharp edges.
• Cut outside the finished line, then file to the correct size.
• Remove burrs after each cut.
• Use a brake, seamer, vise, or form to make controlled bends.
• Fold or roll exposed edges to make them safer and stronger.
• Test-fit the parts before joining them.
• Clean the joint before soldering or brazing.
• Use the correct flux and filler metal for the materials.
• Heat the joint as directed by your counselor.
• Do not touch soldered or brazed metal until it has cooled.
• Include at least one riveted part on one of the two objects.
• Drill or punch matching rivet holes through both parts.
• Keep the rivet holes close enough for a firm joint without weakening an edge.
• Use a rivet type suited to the project and available tools.
• Complete all required methods on both objects.
• Protect bare steel from rust with paint, clear finish, oil, or another approved coating.
• Protect copper or brass from tarnish when the project needs a lasting finish.
• Zinc-plated and tin-plated sheet steel do not require an added oxidation coating for this requirement.
• Clean the projects and remove sharp points before presenting them to your counselor.

Resources

• How To Make a Sheet Metal Box (video)
• How To Prevent Rust (video)

Leader Tips

• Review the pattern, metal, and joining method before cutting begins.
• Demonstrate each new process, then supervise the Scout’s work.
• Check for sharp edges, weak joints, and heat hazards throughout the project.
• Let the Scout complete the measuring, cutting, shaping, joining, and finishing.

Requirement 5B-1: Silversmithing Tools

What You Need To Do

Name the basic tools used by a silversmith. Describe the job each tool performs.

Helpful Tips

• A jeweler’s saw cuts straight lines, curves, and detailed shapes.
• Fine saw blades make narrow cuts in thin metal.
• A bench pin supports the metal while it is being sawed or filed.
• Files smooth edges and refine the shape of a piece.
• Needle files reach small openings and tight curves.
• A chasing hammer forms metal and adds texture.
• A planishing hammer smooths small hammer marks.
• A rawhide, rubber, or nylon mallet shapes metal without leaving deep marks.
• A steel bench block supports metal during hammering.
• A sandbag supports curved metal during sinking.
• Sinking hammers push sheet metal into a curved or hollow shape.
• A dapping block and punches form small domes.
• Pliers grip, bend, and hold small pieces.
• Dividers mark circles and transfer measurements.
• A scribe marks cutting and bending lines.
• A center punch marks the location of a hole.
• A drill makes holes for saw blades, fasteners, or decorative parts.
• A torch heats metal for annealing and soldering.
• A soldering block provides a heat-resistant work surface.
• Tweezers and soldering picks position small parts during soldering.
• A pickle solution removes oxides and flux after soldering.
• Abrasive paper removes scratches and prepares the surface for polishing.
• A polishing wheel or hand-polishing cloth creates the final finish.

Resources

• Silversmithing Tools for Beginners | All You Need to get Started Making Jewelry! (video)

Leader Tips

• Display the tools and let the Scout match each one with its purpose.
• Demonstrate safe use before the Scout handles an unfamiliar tool.
• Include the tools used for sawing, sinking, soldering, cleaning, and polishing.
• Control torches, chemicals, and powered polishing equipment closely.

Requirement 5B-2: Sketch Two Silversmithing Projects

What You Need To Do

Draw two objects that could be made from sheet silver. Show each separate part and include its dimensions, even though the sketches do not need to be to scale.

Helpful Tips

• Choose two projects that can be completed with the available tools and time.
• Possible projects include a pendant, tray, small bowl, box, pin, or decorative plate.
• Draw the finished object from the front or top.
• Add a side view when it helps show depth or curves.
• Draw each separate component used in the project.
• Write the length and width beside every component.
• Include the depth of any bowl, tray, or sunken area.
• Mark all cut lines and sawed openings.
• Mark the location of each soldered joint.
• Show any part that will be sunk into a hollow shape.
• Include holes, tabs, loops, handles, or decorative overlays.
• Allow enough metal around the edges for filing and final shaping.
• Check whether the separate parts will fit together.
• List the metal thickness planned for the project.
• Ask your counselor to approve both sketches and patterns before cutting begins.

Leader Tips

• Help the Scout choose projects that include the required methods.
• Check the dimensions and joints before approving the designs.
• Ask the Scout to describe how each object will be assembled.
• Guide design changes when a part is too small, weak, or difficult to form.

Requirement 5B-3: Make Two Silversmithing Objects

What You Need To Do

Make two objects from 18- or 20-gauge sheet copper using approved patterns. Include a soldered joint in both objects, a sawed component in at least one object, and a sunken part in at least one object, then clean and polish both projects.

Helpful Tips

• Use 18- or 20-gauge sheet copper unless your prior experience allows an approved substitute.
• Sterling silver, nickel silver, or lead-free pewter may be used by Scouts with prior silversmithing experience.
• Use patterns supplied by your counselor or patterns your counselor approved.
• Transfer all cutting lines and dimensions to the metal.
• Wear safety glasses while cutting, hammering, drilling, and polishing.
• Drill a small opening before sawing an interior shape.
• Thread the jeweler’s saw blade through the opening.
• Keep the blade straight and use smooth strokes.
• Let the saw blade do the cutting without heavy pressure.
• Support the metal on a bench pin while sawing.
• File all cut edges until they are smooth.
• Anneal the metal when it becomes hard or difficult to shape.
• Create a sunken part by hammering sheet metal into a hollow form.
• Work from the outer area toward the center as directed by your counselor.
• Use controlled blows to avoid deep dents or torn metal.
• Check the depth and shape often while sinking.
• Clean every soldering surface before joining the parts.
• Fit the pieces closely because solder does not fill large gaps well.
• Apply the correct flux for the metal and solder.
• Place small pieces of solder along the joint.
• Heat the entire joint area evenly.
• Allow the solder to flow through the joint.
• Both finished objects must contain at least one soldered joint.
• Place heated pieces only on a fire-safe surface.
• Use tongs or approved tools to handle hot metal.
• Follow the counselor’s procedure for pickling and rinsing the metal.
• Remove remaining solder, scale, and scratches before polishing.
• Begin with a coarse abrasive only when deep marks must be removed.
• Move through finer abrasives to create a smooth surface.
• Use polishing equipment only with close adult supervision.
• Hold small pieces securely so a polishing wheel cannot pull them away.
• Check both projects for sharp edges and weak joints before presenting them.

Resources

• The Basics of Soldering | Jewelry 101 (video)
• Step-by-Step Guide to Sawing for Handmade Jewelry (video)
• Basic Sinking & Planishing (video)
• How I Clean & Polish Jewelry RIGHT After Casting | Step By Step (video)

Leader Tips

• Confirm the metal, patterns, and required features before work begins.
• Demonstrate sawing, sinking, soldering, and polishing before each process.
• Control the torch, pickle solution, ventilation, and powered equipment.
• Let the Scout complete the measuring, forming, joining, cleaning, and finishing.

Requirement 5C-1: Molds and Their Parts

What You Need To Do

Name the basic parts of a two-piece mold and describe the purpose of each part. Also name at least three types of molds used for metal casting.

Helpful Tips

• The cope is the upper half of a two-piece mold.
• The drag is the lower half of the mold.
• The flask is the frame that holds the molding material.
• The parting line is where the cope and drag meet.
• The mold cavity is the empty space shaped like the finished object.
• A pattern creates the shape of the mold cavity.
• The sprue is the main passage where molten metal enters the mold.
• The pouring basin guides metal into the sprue.
• A runner carries molten metal from the sprue toward the mold cavity.
• A gate is the opening that leads from the runner into the cavity.
• A riser holds extra molten metal as the casting cools and shrinks.
• Vents allow air and gases to escape from the mold.
• Alignment pins help the cope and drag fit together correctly.
• A sand mold uses packed molding sand around a pattern.
• A permanent mold is made from metal and can be used more than once.
• An investment mold forms around a wax pattern that is later removed.
• A plaster mold uses heat-resistant plaster to form the cavity.
• A rubber or silicone mold may be used for low-temperature casting materials.
• Name at least three mold types during your counselor discussion.

Resources

• What Are the Common Types of Metal Casting Process in Engineering and Industry (video)

Leader Tips

• Use a real mold or labeled diagram during the discussion.
• Let the Scout point to each part and describe its job.
• Show how the cope and drag line up before pouring.
• Correct casting terms without requiring memorized definitions.

Requirement 5C-2: Sketch Two Casting Projects

What You Need To Do

Draw two objects you plan to cast in metal. Include the dimensions of every part, even though the sketches do not need to be drawn to scale.

Helpful Tips

• Choose small objects that can be cast safely in lead-free pewter.
• Possible projects include a medallion, nameplate, small figure, token, or decorative shape.
• Avoid thin sections that may cool before the mold fills.
• Avoid deep undercuts that can trap the pattern in the mold.
• Draw the finished object from the front or top.
• Add a side view to show thickness or depth.
• Write the length, width, and thickness beside each object.
• Include the size of every separate component.
• Mark the planned location of the pouring gate.
• Mark the planned location of each vent.
• Place the gate where molten metal can flow easily into the cavity.
• Place vents near high points where air may become trapped.
• Include a parting line when using a two-piece mold.
• Keep lettering and designs large enough to cast clearly.
• Use only designs you created or have permission to use.
• Do not copy copyrighted characters, logos, or artwork.
• Ask your counselor to approve both sketches before making the patterns.

Leader Tips

• Help the Scout choose shapes suited to beginner casting.
• Check the dimensions, gate, vents, and parting line.
• Ask the Scout to describe how the metal will move through the mold.
• Guide changes when a design is too thin, detailed, or hard to remove.

Requirement 5C-3: Make Molds and Pewter Castings

What You Need To Do

Make two molds. Use a pattern supplied by your counselor for one mold and an approved pattern you made for the other. Position the gates and vents, then make a lead-free pewter casting with each mold.

Helpful Tips

• Work only under direct adult supervision.
• Wear safety glasses, leather gloves, long pants, boots, and a shop apron.
• Keep a fire extinguisher near the casting area.
• Place sheet metal beneath the melting pot and pouring area.
• Keep the mold, tools, ladle, and metal completely dry.
• Moisture can turn into steam and throw molten metal from the container.
• Use only lead-free pewter for both castings.
• Make the first mold with the pattern supplied by your counselor.
• Make the second pattern yourself and receive approval before using it.
• Do not use copyrighted designs for your pattern.
• Pack the molding material firmly and evenly around the pattern.
• Separate the mold carefully so the cavity keeps its shape.
• Remove the pattern without breaking the cavity edges.
• Cut or form the pouring gate yourself.
• Add vents where trapped air and gases can escape.
• Clear loose molding material from the gate, vents, and cavity.
• Fit the mold sections together correctly before pouring.
• Place the mold on a level, heat-resistant surface.
• Keep people away from the pouring area.
• Never reach across molten metal.
• Keep the ladle handle away from the edge of the workbench.
• Pour the pewter in one smooth and controlled motion.
• Do not move the mold until the metal has cooled and hardened.
• Treat every casting and tool as hot until checked by an adult.
• Remove the first casting from the counselor-provided mold.
• Make the second casting with the mold you created.
• Cut away the cooled gate and vent metal with approved tools.
• File rough edges and sharp points.
• Wash your hands after handling metal and casting materials.

Resources

• Sand Casting Lesson for Beginners – Step-by-Step (video)

Leader Tips

• Control the melting pot, molten metal, and pouring area at all times.
• Let the Scout make the molds and choose the gate and vent positions.
• Review the mold for moisture, damage, and loose material before pouring.
• Stop the activity immediately when clothing, tools, or the workspace create a burn risk.

Requirement 5D-1: Blacksmithing Tools

What You Need To Do

Name the basic tools used by a blacksmith. Describe the job each tool performs.

Helpful Tips

• A forge heats steel until it is soft enough to shape.
• Coal, charcoal, or propane may provide the forge heat.
• An anvil supports the metal during hammering and bending.
• The flat face of the anvil is used for general forging.
• The horn of the anvil forms curves and rounded bends.
• The anvil edge helps make sharp bends.
• The hardy hole holds tools such as cutters and fullers.
• A cross-peen hammer spreads metal in a chosen direction.
• A rounding hammer moves and smooths heated metal.
• Tongs hold and move hot steel.
• Tongs must fit the size and shape of the workpiece.
• A hot-cut chisel cuts heated metal.
• A punch makes holes in heated metal.
• A fuller makes grooves and helps spread metal.
• A leg vise holds metal during bending, twisting, and cutting.
• A wire brush removes loose scale from hot steel.
• A quench tank cools tools and metal when directed by the instructor.
• A coal rake and fire tools control fuel inside a solid-fuel forge.

Resources

• Basic Blacksmithing Tools (video)

Leader Tips

• Display the tools and let the Scout match each one with its purpose.
• Check the fit of the tongs before hot metal is handled.
• Demonstrate safe hammering, tool placement, and movement around the forge.
• Keep damaged tools and loose hammer heads out of the work area.

Requirement 5D-2: Sketch Two Forged Objects

What You Need To Do

Draw two objects you plan to hot-forge. Include the dimensions of every part, even though the sketches do not need to be to scale.

Helpful Tips

• Choose objects suited to low-carbon steel at least 1/4 inch thick.
• Possible projects include a hook, bracket, handle, fire tool, or small rack.
• Draw the finished object from the front or side.
• Add another view when it helps show bends or twists.
• Write the total length and width on each sketch.
• Include the thickness and shape of the starting steel.
• Mark every taper, bend, twist, hole, and joint.
• Show the location of the decorative twist.
• Show the location of the hammer-riveted joint.
• Include the dimensions of each separate component.
• Mark the amount of steel needed for bends and tapers.
• Keep thin sections strong enough for the object’s purpose.
• Avoid complicated shapes that require skills beyond the available tools.
• Plan the order of heating and forging steps.
• Ask your counselor to approve both sketches before forging begins.

Leader Tips

• Help the Scout choose projects that include the required twist and riveted joint.
• Check the dimensions and planned forging order.
• Ask the Scout to describe how each section will be formed.
• Guide design changes when a part may become too thin or weak.

Requirement 5D-3: Practice Forging Methods

What You Need To Do

Use low-carbon steel at least 1/4 inch thick to forge a taper, a U-shaped bend, a decorative twist, and an L-shaped bend.

Helpful Tips

• Wear safety glasses, natural-fiber clothing, long pants, and closed-toe boots.
• Use tongs that hold the steel firmly.
• Heat only the section that will be worked.
• Work the steel while it is at the proper forging temperature.
• Return the steel to the forge when it becomes too cool to shape safely.
• Draw out a taper by hammering the heated end thinner and longer.
• Rotate square or round steel as needed to keep the taper even.
• Remove deep hammer marks before the steel cools.
• Make the U-shaped bend over the horn of the anvil.
• Hammer both sides of the bend to keep the curve even.
• Reheat the steel when the bend begins to resist the hammer.
• Form a decorative twist in square steel.
• Heat the full section planned for the twist.
• Hold one end in a vise and turn the other end with an approved tool.
• Use steady pressure to keep the twist even.
• Make the L-shaped bend over the edge of the anvil.
• Position the bend line directly over the edge.
• Hammer the unsupported section down to form the angle.
• Check the bend with a square when a 90-degree angle is needed.
• Place hot steel only in the marked cooling area.

Resources

• Blacksmith Basics: How to Draw Out a Taper (video)
• Tapering for Beginners (video)
• Blacksmithing For Beginners – Working On The Horn Of The Anvil (video)
• Blacksmithing for Beginners – Twisting Bar Stock (video)
• Fundamentals of Blacksmithing – Bending (video)

Leader Tips

• Demonstrate each exercise before the Scout begins.
• Watch the steel temperature and tong grip throughout the work.
• Keep other people outside the hammering and hot-metal areas.
• Let the Scout repeat an exercise when more control is needed.

Requirement 5D-4: Forge Two Objects

What You Need To Do

Use low-carbon steel at least 1/4 inch thick to make the two approved objects from your sketches. Include a decorative twist on one object, a hammer-riveted joint on one object, and a finish that protects the steel from oxidation.

Helpful Tips

• Receive your counselor’s approval before heating or cutting the steel.
• Confirm the starting size and length of every steel component.
• Mark the locations of bends, tapers, twists, holes, and joints.
• Follow the forging order shown in your plan.
• Heat only the section being shaped.
• Keep the steel at a safe forging temperature while hammering.
• Use the anvil horn for rounded bends.
• Use the anvil edge for sharper bends.
• Reheat often instead of striking steel that has cooled too much.
• Include a decorative twist on at least one finished object.
• Heat the entire twist section evenly.
• Keep both ends of the twist aligned.
• Include a hammer-riveted joint on at least one object.
• Punch or drill matching holes through the joined parts.
• Use a rivet that fits the holes without excessive looseness.
• Support one rivet head on the anvil or a rivet set.
• Hammer the other end to form a secure second head.
• Check the joint for movement after the rivet cools.
• Remove sharp edges, burrs, and loose scale.
• Use a wire brush after forging as directed.
• Allow the object to cool before applying a finish.
• Protect the steel with wax, oil, paint, or another approved coating.
• Cover all exposed surfaces to reduce rust.
• Check both objects for cracks, weak joints, and sharp points.
• Present the finished objects and sketches to your counselor.

Resources

• Blacksmithing for Beginners – Twisting Bar Stock (video)
• Forging Red Hot Rivet on This Awesome Anvil (video)
• Preventing Rust The Old Fashioned Way And Protecting Some Gifts (video)

Leader Tips

• Review the steel, sketches, and required features before work begins.
• Guide the Scout through each new forging and riveting step.
• Control the forge, hot-metal area, and finishing materials.
• Let the Scout complete the measuring, forging, joining, and finishing.

Living History Program Feature for Scouts BSA

The Living History program feature gives Scouts a chance to experience different cultures, times, and places through hands-on activities and reenactments. Scouts learn about historical events and see how people lived in the past. This interactive approach helps history come alive. For example, while exploring blacksmithing techniques,

Scouts may even use skills learned from the Metalwork Merit Badge to better understand the tools and trades of early blacksmiths. The Living History program feature lets Scouts connect with history by working with period tools, crafts, and traditions, giving them a unique way to learn about the past through real experiences.

More Merit Badge Resources

The Metalwork merit badge gives Scouts a chance to learn how metal can be shaped, joined, and finished. It fits well in the merit badge program because it teaches hands-on skills, patience, and safe tool use. Scouts see how simple techniques can turn raw material into useful items. This adds a practical craft option to the wide array of badges, showing that Scouting includes creative work as well as academic and outdoor subjects.

This badge also connects to others that involve tools and craftsmanship. Scouts who enjoy Metalwork might also explore Welding, Woodwork, or Sculpture. These badges help them try different methods of building and creating. The variety lets Scouts discover interests they may not have expected.

Learn More about Scouts BSA

The Metalwork merit badge supports the larger Scouts BSA program by building confidence and careful work habits. Scouts learn to plan a project, work safely, and complete tasks with attention to detail. These skills help them in leadership roles because good leaders work with focus.

Metalwork also supports personal development and citizenship. Scouts learn how skilled work can serve their troop and community. They also see how safety and responsibility protect themselves and others. This helps them grow into thoughtful, capable young people.

What is the Metalwork Merit Badge?

The Metalwork Merit Badge teaches Scouts basic skills in metalworking, including forging, casting, and sheet metalwork. Scouts learn how to shape, join, and finish metal to make useful items.

Do I need to have experience in metalworking to start?

No experience is required to start the Metalwork Merit Badge. Scouts learn the basics from scratch and get hands-on practice with different metalworking techniques.

What types of projects will I make for the Metalwork Merit Badge?

You will create different metal objects, depending on your choice of metalworking options. Projects may include forged hooks, cast medallions, or items made from sheet metal like small boxes or key holders.

What materials do I need for the Metalwork Merit Badge?

You will need basic metalworking materials such as low-carbon steel, pewter, or copper, depending on your chosen projects. Your counselor will help you select materials that fit the badge requirements.

What tools are used in the Metalwork Merit Badge?

Scouts use tools like hammers, anvils, forges, tongs, files, and rivet tools. For casting, you may also use molds and a melting pot. Your counselor will guide you in safely using each tool.

Do I need to work with a counselor for the Metalwork Merit Badge?

Yes, a certified Metalwork Merit Badge counselor helps guide you through the Metalwork Merit Badge requirements. They will show you techniques, help with tools, and approve your projects.

Is safety gear required for the Metalwork Merit Badge?

Yes, safety is very important. You need goggles, gloves, long sleeves, and sometimes ear protection. Safety gear protects you from sparks, hot metal, and sharp edges.

What are the four main metalworking options for the Metalwork Merit Badge?

The four options are Blacksmithing, Sheet Metalwork, Silversmithing, and Foundry Work. You choose one option to focus on, and you complete projects related to that type of metalworking.

How long does it take to earn the Metalwork Merit Badge?

The time varies. Some Scouts may complete it in a few weekends, while others take longer. Practice, project work, and guidance from your counselor all affect the time needed.

Can I count previous metalworking experience toward the Metalwork Merit Badge?

Yes, some skills or projects may count if they meet badge requirements. Discuss with your counselor to confirm what qualifies.

How can I protect my metal projects from the Metalwork Merit Badge from rust?

To prevent rust, use a clear sealant, oil, or paint on your finished projects. This coating helps protect the metal from moisture and air, which can cause oxidation.

What careers can I explore through the Metalwork Merit Badge?

Careers related to metalwork include blacksmithing, welding, machining, and metal fabrication. The badge introduces basic skills useful for these and other metalworking careers.

The Metalwork Merit Badge teaches Scouts how to shape, join, and finish metal to create useful and decorative items. Through hands-on projects, Scouts learn the basics of metalworking techniques like forging, casting, sheet metal shaping, and sometimes even silversmithing. This badge introduces Scouts to tools like hammers, anvils, tongs, and files and teaches them how to use each one safely and effectively.

There are four metalworking options for Scouts to choose from: Blacksmithing, Sheet Metal, Foundry Work, and Silversmithing. Each option allows Scouts to explore different types of projects and skills. For example, Blacksmithing focuses on hot-forging and bending techniques, while Foundry Work teaches how to make and use molds for casting metal. This flexibility means Scouts can find an area that interests them most and focus on those specific skills.

Safety is a major part of the Metalwork Merit Badge. Scouts learn how to protect themselves with gloves, goggles, and proper clothing. They also learn about safe practices around hot metal, sharp tools, and other hazards. Following safety rules is an essential part of every metalworking project.

Earning the Metalwork Merit Badge can even inspire Scouts to consider careers in metalworking. Whether it’s becoming a blacksmith, welder, or metal artist, this badge provides basic skills and knowledge that could be a foundation for a career in the skilled trades. Scouts who earn this badge gain practical skills, hands-on experience, and confidence in working with metal.