Betty and I have been seeing metal stars decorating houses and thought it looked nice, so I began looking at making them.   After some research, I found theye are called "BarnStars" and are supposed to be for good luck.   These BarnStars are 3 dimensional, have 5 points, and usually have a metal ring around them (I assume for support).    

I will put up some diagrams with angles etc. as soon as I am happy with the numbers.    

Marking and cutting tin pieces.

Two star points marked for cutting.

Several star points marked and cut out.   Notice the elongated diamond is the actual star point, the flap at the upper right is for attaching to the next point of the star.   Next, I'll bend at the marks.

The star points bent and ready to solder.

The star after soldering (on the back side) with some extra points I cut out.

In order to make the ring around the periphery of the star, I bought some 3/16" steel rod and made this board to form it into a circle.   I tucked the free end of the rod under the metal bracket at the top then wrapped the rod around the circle forming it into a circle.   After I had a circle, I welded the ends together.   You can see the marks every 72%deg; around the board help me assemble the star.

This was an angle bracket that I bent and screwed to the wood to hold the end of the rod while bending.

The end result tin star.   I couldn't weld the star to the ring, I even tried to reinforce the star tip contact points with nails but it didn't work (for me, I'm not a great welder).

This pic shows the 3D attribute of the star.

I bent then welded a small angle brace at the top as a hanger, but I won't use this star.

Here is my initial drawing on paper of the template for the barnstar's point (one of 5).   These star points are one of the most difficult objects to draw and cut out since there are NO 90° angles.   So I decided to made a template.   I think the most accurate way to do this is take the Tan of each angle and draw them using rise over the run (Y/X) instead of a protractor.   The angles at the top are 22° and the angles at the bottom are both 40°.   The star point length for a 10" star is 5".

I needed something durable for a template and I happened to find this Blu-Ray Disk cover (we put all our DVDs in a cd book, it saves a lot of space).   Here I have marked the center line with dots at each end (5" for a 10" barnsatar), and the angles at each end.   Next I will extend the lines until they cross and draw a flap (or tab) on one of them so each point of the star can be welded to the one next to it.

Close up of the template with angles extended and the tab drawn.   I later discovered the tab had to be trimmed a little bet at the top so the resultant star points would fit.

The cut out template.   The Blu-Ray box is tough (good for a template) so I had to use small tin snips to cut it out.

Here ate acouple of the star points marked on 22 ga. steel.

The five star points cut out with the template.

Trial fit, note the tabs are bent a little too far.   This is where I figured out I had to cut a little off the tab at the top so the star points would overlap correctly.