Ava Monroe
Making a cross from cut nails is a popular religious craft, especially around Easter. It can be a fun activity for both children and adults and the finished product can be used as a pendant, key chain, or wall decoration. The process involves using a combination of nails, glue, wire, and rope to create a rustic cross design. For those who celebrate the resurrection of Christ, using nails for the cross can hold symbolic meaning. In this article, we will explore different methods for creating a cross from cut nails, including the simple wooden cross necklace and the more intricate Jerusalem cross.
| Characteristics | Values |
|---|---|
| Type of Nails | Cut nails, horseshoe nails, old nails, antique nails |
| Nail Size | 2-inch nails, #6d common nails, #5 horseshoe nails |
| Additional Materials | Copper wire, glue dots, leather or hemp cord, wire brads, rope, braze material, jig made from scrap wood, wire cutters, pliers, MAPP gas torch, oxy-acetylene torch, carbon arc torch, arc welder, vice grips, wire |
| Craft Type | Religious craft, Easter craft, Sunday School craft, Christmas tree ornament, necklace, pendant, wall cross |
| Craft Time | 5 minutes, 15 minutes |
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What You'll Learn
Choosing the right nails
When it comes to choosing the right nails for your cross, there are a few things to consider. Firstly, decide on the type of cross you want to make. For a simple wooden cross necklace, you can use cut masonry nails, which are typically available in 2-inch sizes. Alternatively, for a rustic look, you can repurpose old rusty nails from dismantled pallets, ensuring you have nails of two different lengths.
If you're creating a Jerusalem cross, antique cut nails are a great option. These nails, such as the #6d common nails, are around 2 inches long. Select eight nails that are similar in appearance and free from defects. For this type of cross, you will need a torch to heat the nails, so ensure the nails you choose can withstand high temperatures.
For a horseshoe nail cross pendant, you will need #5 horseshoe nails and a variety of pliers, including diagonal wire cutter, needle-nose, small vice grip, and wire cutter pliers. This type of cross requires bending the nails, so ensure the nails are made of a malleable material that can be shaped without breaking.
If you're making a cross necklace for children, safety should be a top priority. Opt for nails that are small enough to be comfortable and non-hazardous for kids. You may also want to consider using glue dots instead of hot glue or super glue to avoid creating a tight bond that could be difficult to adjust.
Lastly, if you're creating a wall cross, you can use antique cut nails for a beautiful religious art piece. Consider the length and thickness of the nails to ensure they are proportionate to the size of the wall or display area. You may also want to include additional materials such as wire brads to attach the cross to a backing, such as an 8-sided piece of finished walnut.
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Preparing the nails
Firstly, select the nails you will be using. For a simple cross necklace, you will need four 2-inch-long cut nails. Try to choose nails that are similar in appearance and free from defects. If you are creating a Jerusalem cross, you will need eight nails.
Before assembling the cross, ensure the nails are soft enough to cut and drill. Heat the nails with a MAPP gas torch, oxy-acetylene torch, or carbon arc torch until they are red hot. Allow them to cool slowly in the air. Once cooled, use a tool like a Dremel to lightly grind away any sharp edges that may be present from the cutting process.
Now you can begin to assemble the main cross. Place four nails end-to-end on a firebrick, aligning them 90 degrees apart. Use a piece of paper to ensure the corners are square. Fine-tune the layout until you are satisfied with the appearance. Secure the nails in place by heating them with the torch and melting brazing rod onto the joints. Be careful not to bump the nails out of alignment during this process. If adjustments are needed, reheat the joint and use pliers to reposition the nails.
Once the main cross is assembled, set it aside and focus on the remaining four nails. Place one nail in a vise and wrap masking tape around it. Measure and mark 7/16 of an inch (or 11 mm) from the head, and cut the nail at this mark with a Dremel tool and a thin cut-off wheel. Repeat this process for each nail, keeping the pairs matched to ensure consistency. After cutting, remove the tape and grind away any burrs created during the cutting process.
With the nails prepared, you can now proceed to assemble the full cross.
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Bending and shaping the nails
Selecting and Preparing the Nails:
Start by choosing the right type of nails. Antique cut nails or old rusty nails can add a unique, rustic charm to your cross. Ensure you have nails of similar appearance and without defects. For a cross necklace, you'll need four 2-inch masonry cut nails, while for a wall cross, you can opt for #6d common nails of the same length.
Before shaping, it's important to soften the nails. Use a MAPP gas torch, an oxy-acetylene torch, or a carbon arc torch with an arc welder to heat the nails until they turn red-hot. Allow them to cool slowly in the air so they become soft enough for cutting and drilling. Don't forget to wear proper safety gear, including heat-resistant gloves and eye protection, during this process.
Bending and Assembling the Main Cross:
To create the main structure of the cross, place four nails end-to-end on a firebrick, aligning them at 90-degree angles to form a cross shape. Fine-tune the layout by eyeballing it from different directions and making minor adjustments for a symmetrical appearance.
Use your torch to heat the nails, then apply brazing rod to the joints. The heat will melt the brazing rod, allowing it to flow and fuse the nails together. Be cautious, as it's easy to bump the nails out of alignment. If adjustments are needed, reheat the joint and use pliers to reposition the nails gently.
Once the brazing has cooled slightly, carefully remove the main cross assembly from the brick with pliers. Remember, the assembly will still be hot, so take precautions to avoid any burns.
Shaping the Smaller Crosses:
For a more intricate design, like the Jerusalem cross, you'll create smaller crosses to overlay on the main cross. Cut the head end from four additional nails, using a vise and a Dremel tool with a thin cut-off wheel. Mark the cutting point at 7/16 of an inch or 11 mm from the head. Keep the cut pieces matched and avoid mixing them with parts from other nails.
Remove any burrs left by the cutting process with a grinding tool. This step requires patience, as it's easy to knock the small crosses out of alignment during brazing. Braze the joints one by one, carefully monitoring the layout to ensure precision.
Drilling and Finishing:
Drill a hole at an angle on the top nail of the main cross to create a loop for the cord or hanging mechanism. Insert a wire brad, and lightly grind away any sharp edges. Bend the wire brad with needle-nose pliers to form a smooth and round loop.
You can now add the smaller crosses to the main assembly. Use brazing techniques to attach them securely, being mindful of the overall alignment and symmetry. Finish the cross by polishing or adding a patina, depending on your desired aesthetic.
Crafting a cross from cut nails requires precision and patience, but the end result is a beautiful, symbolic piece of art.
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Joining the nails
Preparing the Nails:
Start by selecting similar-looking nails without defects. For a wall cross, you will need eight nails, and for a necklace, four 2-inch masonry cut nails are typically used. Place the nails on a piece of brick or a firebrick and heat them with a torch until they are red hot. Allow the nails to cool slowly in the air so they soften, making it easier to cut and drill them later.
Aligning the Nails:
For a wall cross, place four nails end to end, aligning them 90 degrees apart. You can use a piece of paper to ensure the corners are square. Eyeball the layout from different angles and make adjustments as needed for a symmetrical appearance. For a necklace, bend four nails at 90-degree angles, two at 1 3/8 inches for the left side and two at 3/4 inches for the right side, using needle-nose pliers to create a rounded look at the top of the cross.
Joining Techniques:
To join the nails for a wall cross, use a brazing technique. Heat the nails with the torch so that the brazing rod melts on the joints. Carefully guide the flow of the braze by changing the direction of the torch. If the nails move out of alignment, reheat the joint and use pliers to reposition them. For a necklace, you can join the nails with wire. Cut two pieces of wire, about 32 inches each, and lock the left side nails together with pliers. Wind the wire tightly from the tip of the pliers towards the center of the cross, maintaining tension on the wire. Repeat this process for the right side, then cross the wire to the other side and continue winding to the bottom of the cross.
Finishing Touches:
After joining the nails, there may be sharp edges remaining. Lightly grind these away to create a smooth finish. For a wall cross, you can add a hanging mechanism by drilling a hole at an angle and inserting a wire brad. Bend the wire into a smooth, round loop with needle-nose pliers. For a necklace, use glue dots to hold the nails together, and then wrap the center with rope or cord for added security and a decorative touch.
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Finishing touches
Once you have the basic structure of your cross, there are several ways to put the finishing touches on your creation. You can use glue dots to hold the nails together, but for a stronger bond, you can use super glue or a sealant. If you use hot glue, be aware that it dries hard and may create an unwanted space between the nails.
If you are making a cross necklace, you can wrap rope or cord around the centre of the cross to secure it. You can also use wire to bind the nails together. For a necklace, you will need to create a loop at the top of the cross, which you can do by drilling a hole at an angle and inserting a wire brad. Bend the wire into a loop with a pair of pliers.
If you want to hang your cross on a wall, you can mount it on a piece of wood or a pallet, securing it with wire brads and braze. Alternatively, you can create a wall cross by brazing nails directly onto a firebrick.
Your cross is now complete and ready to be displayed or gifted!
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