Aluminum Shackles

Ideas and instructions how you can make your own bondage toys.
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MSpike
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Aluminum Shackles

Post by MSpike »

Here is a set of DIY shackles made from aluminum bar stock. They don't use a hinge, they have an interlocking tab and slot arrangement. Details should be visible if you open the photo and enlarge it.

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AlShack (1)small.jpg
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AlShack (3)small.jpg
The material is 1 inch (25 mm) x 1/8 in. (3 mm) aluminum flat bar. Tools include a vise or sturdy C-clamp, drill with bits, small file, and a saw. Any saw is OK on the aluminum, it does not need to be a metal-cutting saw. A coping saw, which looks like a giant wire cheese cutter, and has a narrow blade which can be removed from the frame and inserted in a hole is good for making the slots.

Measure around your wrist or ankle and add 2 -3 inches for the tabs and a fairly loose fit, then divide the length by 2 and cut 2 pieces of bar. Saw off the sides of the end of one piece so there is a 1/2 in. wide by 3/4 in. long tab on the end. Clamp the tab in a vise or to a strong object, and bend the tab at a 90 degree angle, 1/8 of an inch from where it joins the full width of the bar.
Drill 3 or 4 overlapping 3/16 inch or slightly larger holes across the other piece, about 3/8 in. from the end, to form a slot that the tab will fit in. Clean up the slot and the edges of the tab with a file. Carefully clamp and bend the slotted piece 90 degrees at the slot. Go slowly, but the piece may still break at the ends of the slot.
Make sure the tab and slot interlock, then start forming the bars to fit around the wrist or ankle. Clamp the bar, make a gentle bend, move the bar down in the clamp, and make another bend, repeat. If you have a large iron pipe or similar, you can clamp the bar to it and use it as a bending form.
You will finish with two U-shaped parts which will overlap at the plain ends. Mark where they overlap, and bend the ends outward at 90 degrees to form full-width tabs for fastening. Interlock the tab and slot and adjust the fit as needed. Cut the ends to the length you want (they can match, or one end can be longer for an extra attachment point). Clamp the tabs together and drill a hole for a fastener, and another for attaching a chain, if you left one tab longer.
I use a small lock or a small D-shackle to hold the pieces together and attach a chain, but for long-term wear a small hole for a pop rivet and a larger hole for a chain/lock would work.

Variations: The parts do not have to be the same length. A long U and short, straight part could make "Darby-style" cuffs, or two U's with slots on one end and a bent tab on the other could attach to a straight bar with tabs on the ends and matching holes to attach the bent tabs toward the middle.

Making these things is almost as much fun as wearing them, especially if you wear one set while you make another (but be careful).

Mar Lingspike
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bound_jenny
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Re: Aluminum Shackles

Post by bound_jenny »

That's wonderful craftsmanship! Very nice work. :D

Jenny.
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Old Timer
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Re: Aluminum Shackles

Post by Old Timer »

"Making these things is almost as much fun as wearing them, especially if you wear one set while you make another"

That and anticipation are more than half the fun!
"Everything is relative to the observer"
"You don't get to be old by being a fool"
BornThisWay
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Re: Aluminum Shackles

Post by BornThisWay »

Nice work! I didn't think you would be able to bend aluminum like that without it cracking.
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