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.|