How to Make Copper Ball Headpins with a Butane Torch

Copper ball headpins with smooth rounded ends

Copper ball headpins are easy to make using a butane torch and bare (uncoated) jewelry wire. This tutorial shows how to create smooth ball ends, with tips for working with thicker wire.

Tools and Materials for Making Copper Ball Headpins

To make copper ball headpins, you will need:

• Bare copper wire (16g–24g) for making headpins
• Butane torch for jewelry making
• Flush cutters or wire cutters
• Chain nose or needle nose pliers
• Heat-safe surface such as a fire brick or soldering block
• Bowl of water for quenching
• Pickle solution or citric acid for cleaning copper (see below for recipe)

Setting Up to Use a Butane Torch

Before you begin, set up a safe workspace for using your torch.

• Work on a heat-resistant surface such as a fire brick or soldering block. 
• Keep a bowl of water nearby for quenching hot metal.
• Make sure you have a fire extinguisher nearby in case of an emergency.
• Light the torch and adjust the flame so it is steady and controlled. Use a torch that will stand by itself on a base so you can keep both hands free.
• A small butane torch provides enough heat for copper wire, but flame position and control are important for consistent results. A torch that can be adjusted to a tight flame works the best.

Step-by-Step: How to Make Copper Ball Headpins

Step 1: Cut the Wire

Cut a piece of copper wire slightly longer than your desired headpin length. Fold one end of the wire into a small, tight curl where the ball will form. This step is optional, but it can help create more consistent ball sizes.

Step 2: Hold the Wire

Hold the wire parallel to the flame, especially for thicker gauges

Grip the wire with pliers, leaving the folded tip exposed. Position the wire parallel to the flame, keeping your hand safely off to the side. This positioning helps concentrate heat at the tip, allowing the process to work with both thin and thick wire.

Step 3: Heat the Wire Tip

Place the tip of the wire in the hottest (blue) part of the flame. Focus the heat on the very end. As the copper heats, it will melt and begin to form a ball.

Step 4: Let the Ball Form on the End of the Wire

Allow the molten copper to gather into a smooth, rounded shape at the tip. Remove the wire from the flame as soon as the ball forms.

Step 5: Quench the Headpin in Water

Place the hot wire into a bowl of water to cool it.

Step 6: Repeat to Make More Headpins

Repeat the process to make additional headpins.

Step 7: Clean off the Fire Scale

Clean the copper to remove oxidation using a pickle solution. See below for instructions on making a simple, non-toxic pickle from common household ingredients.

What Size Wire Works Best for Copper Headpins

• 22-24 gauge: easiest to melt and form smooth balls
• 20 gauge: works well with controlled heat
• 16-18 gauge: requires more heat and proper wire position in the flame. Takes longer.

If you are new to making headpins, start with thinner wire and work up to thicker gauges when you have the technique down.

How to Clean Copper Headpins Using Pickle

Copper ball headpins after pickle, before pickle and with a 'red' head made by quenching while hot

After heating, copper develops oxidation (fire scale) that can dull the finish.

Pickle is a mild acidic solution used to remove this oxidation after torch work. You can use a commercial pickle or make a simple, non-toxic version at home.

How to Make Homemade Jewelry Pickle

A common non-toxic homemade pickle can be made using white vinegar and salt:

• Mix 1 cup white vinegar with 1 tablespoon salt
• Heat gently in a microwave or on the stove (do not boil)
• Pour into a glass or ceramic container

Alternatively, you can use citric acid:

• Dissolve 1–2 tablespoons of citric acid in 1 cup of hot water

Or you can buy jewelry pickle and follow the manufacturer's instructions. Sparex is a common brand.

How to Use the Pickle Solution to Remove Fire Scale

• Place cooled headpins into the solution
• Let them sit until oxidation is removed
• Remove using plastic or copper tongs (not steel)
• Rinse thoroughly in water and dry

Always use non-reactive containers and tools when working with pickle, and avoid placing steel in the solution since it can contaminate it.

Tips for Smooth Ball Headpin Ends

• Keep the hottest part of the flame focused on the tip of the wire
• Hold the wire steady while heating
• Remove heat as soon as the ball forms
• Avoid overheating, which can distort the shape
• Practice with thinner wire before moving to thicker gauges

Troubleshooting 

The headpin ball won’t form

The torch may not be hot enough or you are not holding the wire in the hottest part of the flame. Try repositioning the flame or using thinner wire

The headpin ball is uneven

Heat may be uneven. Adjust flame position and keep the wire steady

The wire melts too much or the ball falls off

The wire is overheated. Remove the wire from the flame sooner

Ways to Use Copper Ball Headpins

Copper ball headpins are useful for:

• Earrings
• Bead dangles
• Charms and drops
• Wire-wrapped components

Making your own headpins allows you to customize length, gauge, and material for your designs.