I tried a rectangle sized to fit a set of weights in a Priority Mail Small Flat Rate Box. It came out 2 1/2" x 5". I immediately didn't like it and dismantled it to use the shot again. I decided to play with a round shape. I finally worked out a design I like and here's how I did it.
|Make a fine gauge thumbtack equivalent|
|Pin in the aluminum scrap|
|Tape applied to aluminum to prevent scratching the machine|
|Repeatable radius jig|
|Pin taped down at 1 1/4"|
|Circle sewn, opening left for filling|
|2" radius set up|
|Here's a close-up of the pin through the fabric.|
After I sewed the circle I cut off the excess fabric with my $3.99 Harbor Freight soldering iron. This glass table makes it a cinch to cut and seal these man made fibers.
|Cut around the sewn line with a soldering iron|
|Hemostat helps turn right side out|
|Turning circle with the hemostat|
|Turning circle with the hemostat 2|
|To finish turning I use an 8mm wooden knitting needle|
|Push the edges out and finger press the seam|
|Weigh out half a pound of lead shot|
|Add lead shot to the secondary containment vessel|
Poke the excess fabric back in the hole and sew it up on the sewing machine. This is the inside part so it won't show.
|Sew up the opening on the secondary containment|
Turn the excess fabric into the opening after the pink lead filled bag is in there. Sew all the way around the edge of the circle so the closing stitches blend in and look on purpose. I use my seam guide at an angle to sew right at the edge of the bag.
|Seam guide helps sew right at the edge.|
********* Update *********
I made a bunch of these out of some fabric with circle designs on it that I had left over from making a floor cloth. These are for sale on my Etsy store for Fall 2018. I'm happy to share my process so people can make their own, but if you use my instructions to make these to sell please send me a commission. 10% sounds fair. I take PayPal.
I got some 3" stockinette from Amazon (sold for bandages) to make the secondary containment. I stitched it with a 2 1/2" radius.
I got some more lead scuba weights used on ebay. This kind has larger shot. I can kind of feel the difference in the weight but I still like it.
|Contents of 4 lb Sea Pearls Scuba Weights bought on eBay|
I found a new technique for holding the weights in while I sewed the secondary containment closed too. Bobby pin.
|Bobby pin keeps lead shot out of the way while I sew the knit pouch closed.|
I like these a lot. The fabric really works. This polyolefin is very good for this use as the color is heat sealed into it. You can't stain this stuff so by extension I think it should be very unlikely to bleed.
|Design side, set 1|
|Design side, set 2|
|Reverse side, solid camel 100% polyolefin|
|3 3/4" diameter|
|about 1/2" thick|
|In use as poster weights|
|Design side and back side shown|
|Hand to show scale. Weights are easy to pick up by the thinner edge|
|The thinness of the weights allow them to be used inside flat files|
|Set of poster weights on a flat file cabinet full of posters|