Pick a design based on your skill level as a metal worker and desired function of the fan. A large fan is used for slow dancing and a small and agile fan for quick technical moves. Look at websites that sell fire fans for design ideas.
Prepare steel rods for welding. Measure and cut thin, non-coated steel rods with an electric saw. Sand rough edges with an electric sander.
Weld steel rods and steel circles together to match your design.
Sand excess metal and rough edges with the electric sander.
Drill two small holes with an electric drill about 1 1/2 inch apart in each rod's end where Kevlar will attach.
Sand rough edges with the electric sander.
Cut Kevlar to the proper length. Determine the amount of Kevlar needed for each wick by wrapping the Kevlar around a rod until you reach the desired thickness. Cut a piece of Kevlar that length for each wick with a pair of scissors.
Attach the Kevlar to the rods. Wrap the Kevlar around each rod and stick non-coated metal wire through the Kevlar and drilled holes. Cut the wire so it extends 1cm beyond the Kevlar in each direction. Use pliers to fold the wire back into the Kevlar, securing the wick.
Sew down the end of the Kevlar for extra security. Use Kevlar thread and a needle for for this task.