I thought it would be fun to share how I make my holiday coal soap with a tutorial. If you’re a soaper – enjoy the instructions. If you’re not a soaper, you might still enjoy the wacky humor and inside info I’m about to share.

I make fabric bags to stash my lumps of coal. But these also work well in purchased drawstring bags, a little stocking, or maybe decorate a glassine or brown paper bag. Consider stamping, sewing, drawing or whatever media you like to decorate with. Get creative with the packaging, that’s where YOUR style really comes out and makes this project your own.

NOTE – lots of people make coal soap using melt-and-pour soap from the hobby store, and use a rock mold to shape the coal. My skin is not fond of melt-and-pour soap formulas, so I prefer the old-school, hard-core, cold-process method.
I made up a batch of cold process soap and colored it black. Here’s a guideline of how I did it. This is not a “how to make soap” tutorial. I assume you already know how to make soap if you’re trying this project. I’m just sharing how to turn soap into lumps of coal. MMM-kay?
- soaping oils of your choice, and the correct amount of lye for them (use a soap calculator)
- 40% lye solution (means 40% lye in my water, in other words – this is a pretty decent water discount, consult lye calculator)
- bamboo charcoal – 1 tsp PPO is typical, I used a bit less since my FO discolors brown and helps darken the soap
- Fragrance of your choice – I LOVE Santa’s Pipe from Sweet Cakes for these lumps of coal
Since you’re going to hand mold the lumps later on – we really don’t care how ugly the soap is in the mold. You can soap it pretty warm like 120 F. Dump the charcoal and fragrance into the oils, then add your lye water and stir until you get trace. Thick trace is fine. Heck, this stuff went nearly solid on me and I pretty much packed it into the mold rather than poured it. Tunnels, ugly tops, we don’t care! Insulate to make sure it goes through gel phase and let it get as hot as possible without a volcano. (although black soap volcanoes would be really cool, right? Save that for the next science fair project.)
Another NOTE – If I were really smart, I would hot process this stuff. But I’m so used to cold-process so that’s how I make these. With the 40% water discount, sufficient gel phase, and the 1 ounce size, these little guys cure pretty fast.
Finally, lets get started.
Cut your black soap into bars and then cut each bar into 4 pieces. This gives me about 1 ounce of soap in each piece…

I want metallic veins in my soap, so I’m using 3 different cosmetic powders from TKB trading. I used holographic glitter (super irridescent!) along with blackstar gold and antique silver. Use whatever you have or skip the vein step.
Oh! See that dust mask? You will need one if you’re going to sift micas around! Don’t skip it – your lungs will thank you later!!!

Just put a little sparkly powder in the tea ball and sift it over the top of all your pieces. ..

Then I turn each piece over and sift more powders on top.
I am willing to admit I was too heavy-handed with the micas on this batch. You can use much less than the photo and be just fine.
The photo below has all the soap pieces dusted with all 3 of my sparkly powders (2 micas and 1 glitter that sparkles greenish in the photo)

Now it’s time for physical labor. Put on some gloves for this. (No, it’s not optional, put on the dang gloves)
Grab a piece of soap…

And smush…

I suggest using 2 hands, but I needed one hand to take the picture. (I’ll let you do the math on that one)
Keep smushing like you’re molding clay…

Is anybody else chanting “2 by 2, hands of blue?” or am I the only one who channels River Tam when I wear nitrile gloves?

You just want to get some of the sparkly powder into the inside of the lump, then smooth the outside into a lumpy looking thing…

I don’t like the jagged edges so I smooth those out. They will come off in the first wash anyway. Here’s a finished lump….

Here’s a tip about shaping your lumps…make them fat and not skinny. Skinny ones look like lumps of turd and not lumps of coal. Here, I’ll show you…
See the turd looking thing on top, and the coal looking thing on bottom?

(I will humbly confess that the lumpy turd idea took on a life of its own. There are tons of things you can do with soap in that shape. A few family members should be expecting Mr. Hanky soaps in their stocking this year. But let’s try to stay on task here with the coal, shall we???)
OK. Now you just repeat the smooshing chunks into lumps for all the gazillion little soaps in your batch. Yep, it’s tiresome. Yep, your hand might cramp up. I thought I would never finish smushing the 72 lumps in this batch. But I did, and I lived to write this post. Here’s a pile of lumps…

They are perfectly fine that way in the photo above. But I didn’t like all the gold on these so I decided to rinse them with water to get rid of some surface powder. I swished each lump in a bowl of warm water and laid them on some plastic canvas to dry.
See the suds on the soap? We don’t like that. It leaves a film. Get out your bottle of alcohol and spritz…

See, the alcohol killed all those bubbles instantly. Now the soap is shiny and not so gold.

Here’s a whole bunch of them, as they dry off…

Another group pic of a happy bunch of lumps…

I cut one open to show the veins of sparkle inside. These will begin to show on the outside when the soap is used and gets smaller.

Now take your lumps….

…And let them cure or dry out for a couple of weeks and then package them up for the holidays. Since these are small, the water evaporates more quickly than in a 4-5 ounce bar soap (the discounted water in the formula helps there too).
These little lumps should be ready to use much faster than your typical cold-process soap. (two weeks for me, but your mileage may vary depending on the oils you used, as well as humidity and other such variables.) As I stated earlier, making these with the hot process method is probably a better way to go. I’ll try to remember that for next Christmas.
I’ve already sold out of my first batch of coal and had to make more before the holiday season really gets started. So it seems these little lumpy critters are popular? If this whole process is too cumbersome for you, pop over to my Ballyhoo Bath Etsy shop where I have these for sale in handmade fabric bags.
Howdy-Ho and Happy Holidays!