Tuesday, June 30, 2015

Deputy Star 3d Box Assembly Guide

Fun dimensional box (base plus lid) is great 
for western or cowboy style event, party, or as a gift box. 
Measures approx. 5" tall x 5" wide x 1.5" deep. 
Box lid includes shape that echos in angular edges 
the knob-pointed pentagram star. 
Accent top shape has cutouts with backside shape 
to show through opening cuts, edge thick-line shape, 
and "DEPUTY" letter cutouts (with positioning template). 
Base for box is simpler star shape cut as one piece, 
with accent panels to cut from a colorful paper. 

1. Identify and cut the shapes:
A one-piece base with sides and rim
B base accent shapes (5)
C lid main star shape
D bottom lid boxing strip
E top lid boxing strip
*F lid front accent with contrast, letters
G accent star rim
H lettering template
*NOTE the "blue" contrast shape has been modified in the final file version

2. Prepare the base shape by folding back along all perforation lines, folding forward at side extensions side end tab.

3. Fold the first side section of the star-shaped base box perpendicular to the main star shape, and fold back the free part of the extension to form one of the star point sides. Tuck the bottom edge tab inward toward the base box's interior to align the tab's perforation line at the adjacent free straight edge of the star floor. Glue in place.

It will assist the gluing and attachment of the floor tab seam to place the assembly flat on a hard surface and press thumb or finger into the point area along the tab/seam areas.

4. Fold the adjacent side section up in similar fashion, align the end straight edge at the first strip's end tab "valley" fold, adjust so that top and bottom of boxing strips line up, and glue in place.

5. Continue to assemble the rest of the base box following the assembly in steps 4 & 5 until all strip extension tabs and edges are attached.

6. Apply glue to the underside of each of the (10) rim tabs, fold toward the inside of the box and glue in place.

7. Bend each of the accent strip sections forward at the center vertical perforation. 

Position one on each side section of the base box, with perforations of each lined up, accent strip center (offset from edged) on the boxing strip.

8. Prepare the top (long) and bottom (short) lid boxing (side) strips by bending on the vertical perforations to follow the in/out direction of the lid main star edge shape.

9. Identify the center of each strip to get familiar with how they will be attached to the main lid star. Shown here is the top strip, and the area pointed to is the inner angle position.

Shown here is the bottom strip with the center of the bottom angled position being pointed to. This joint is marked with "+" in each tab.

10. Continue preparing each lid boxing strip by bending inard the top tabs row at perpendicular angle.

Fold bottom tabs upward and glue in place on the backside of the strip, EXCEPT leave the tab opposite the short end tab flat.

11. Position the bottom boxing strip first, with the center marked perforation line aligned at the inner angle at the bottom of the star.

Once you have the correct positioning established . . . 

. . . line up and join the long tab to the corresponding star edge.

12. Continue to bend, align and join each star section edge to the corresponding tab section's perforation edge.

Work along the first half of the boxing strip until completely attached, then repeat for the opposite half.

13. Attach the top strip to the attached bottom strip end, with tab under the new strip's end straight edge.

(NOTE: you can see the unattached bottom tab still unfolded.)

14. Position edges and perforation lines of the newly-attached boxing strip and lid star until all edges except the final 1-2 are left to attach.

In one motion, fold the end tab behind the first, attached strip's end straight edge while at the same time lining up the final star edges and tab perforation lines to complete the attachment of strips and star.

15. Fold back the final rim tabs and attach.

16. Prepare the accent lid star shape by positioning and attaching the contrast shape behind the accent star.

NOTE:  the accent shape has been modified for the final file version by expanding taller to underline the bar cut openings as well as the stars.

17. Position and attach the rim outline on the accent star.

18. Position the letters for "DEPUTY" onto the accent star. One way to do this is to use the template provided in the file, centered in the space between the bar cutouts, and side to side, then temporarily in place with temp tape or equivalent.

Position and glue each letter in place on the star through the appropriate "window" of the template, then . .

 . . . . carefully remove the template, leaving the letters in their appropriate spacing and position.

19. Position and attach the accent star front onto the star of the assembled lid.

It may be helpful to turn the lid face down on flat surface and apply finger pressure from the back side to ensure complete attachment.

Here is the completed star box.

Saturday, June 27, 2015

Kickin' It! 3d Cowboy Boot Assembly Guide

New "Kickin' It!" 3d boot design
featuring fringe trim plus stars and stripes panels
(or other paired paper combinations you choose)
Measures approx. 8" tall x 6.25" long x 2.5" wide. 
Contrast upper rims and straps, shoe top fringe shape, 
layered sole, dimensional heel with inner support strip. 
Brad fastener or stud embellishments on side straps, fringe. 
Attached three-layer "Kickin' It!" tag says congratulations, 
or good luck, or well done. 
Fun patriotic or western party or decor display. 
(You'll be surprised how easily this design assembles!) 

1. Identify and cut the shapes:
A "upper" left side front & side back panels
B "upper" right side front & side back panels
C front upper rim shape
D back upper rim shape
E top tabs, left & right
F fringe strip
G shoe "lower" center back
H & I left and right shoe back sides
J & K left and right shoe front sides
L shoe center front with contr. underlay
M shoe sole
N tread shapes for buildup (4)
O heel inner support strip
P heel box shape
Q tag three layers

2. Prepare the side panels by folding back slightly on all vertical perforation lines.

Join both pairs of left and right side panels at center seam by overlapping the straight center edge to the adjacent tab perforation line, adjusting to match top and bottom edges.

Note that the "right" side pair will have a tiny square cut out symbol in tab areas or near center edge at bottom. This will assist in orienting all the shapes that should be assembled on the "right" side of the boot, since the boot IS NOT symmetrical, and it does matter for placement.

3. Join the left and right side assemblies at the front and back center seams to form a tube.

4. Prepare the rim strips by bending sections back slightly on all vertical perforations.

NOTE that the front rim strip includes the tiny square symbol on the side end that will align at the right side seam (symbol should still be visible on the inside of the boot tube).

5. Position the front rim strip over the front top of the boot, aligning top edges, perf lines. side edges at side seams.

6. Fold the top tabs in half. Position right side (with square symbol cut out) to enclose the right side edge/rim. Line up the punch holes and glue the area around the holes (outside)  and inside tab area in place.

Repeat for the other strip and left side.

7. Prepare the shoe center back section by folding back slightly on all perforation lines, including the narrow wedge tabs, and bottom sole tabs.

8. Overlap the side section straight edges to the wedge tab perforation and glue in place.

9. Prepare the left and right back side shoe sections by folding back on perforation lines.

The right back side section includes the "R" mark in the tab, in case there is a question about assembly position.

10. Join the two portions of the back side seams.

11. Prepare left and right shoe side front sections by folding as with other sections.

12. Position lower portion edge to overlay adjacent back side section tab to perf line and glue in place. 

Bend to align the upper portion straight edge to align at corresponding tab perforation line, and glue in place. Complete both sides in similar manner.

13. Prepare center front panel by bending bottom tab back, next perf line also as "mountain" fold, bending next two perf lines as "valley" folds.

14. Position and glue the contrast underlay shape behind the upper two portions of the center front panel, matching the perforation lines of each, and centering offset within side/top edges of front panel.

15. Position center panel along front edges of shoe assembly, align corresponding edges and tab perf lines, and attach both sides, working along each edge a section at a time.

16. Bend all of the sole edge tabs under along bottom of sole.

17. Identify the "R" on both shoe assembly tab and sole that will show where the right side of the sole should be attached. 

Dry-fit to get an idea of how the sole will attach.

18. Line up and attach the back sole edge at the back tab perf line.

Line up and attach the front sole edge at the front tab perf line.

19. Work along both edges to line up and attach sole edges at each portion's tab perf line, using the sole finger opening cutouts to assist with alignment and securing.

20. Fold each of the four tread perf lines back slightly. One by one, attach the tread shapes into one thick shape. As each is attached, re-bend to make sure the sole is flexed into the bent shape.

21. Apply glue to the sole margins and heel area. Position and attach the tread buildup shape to the bottom of the shoe.

NOTE: this attachment will take some time and patience to ensure that that all edges adhere as thoroughly as possible. Reach in to shoe interior to assist with pressure to attach tread.

22. Prepare the heel box shape by folding back on all perforation lines and tabs.

Identify the "R" cut that shows which edge will attach to the bottom of the shoe assembly, at the right edge.

23. Build the heel box bottom by bending sides into shape to align bottom (with R) straight edges at corresponding tab perf lines.

24. Prepare heel inner support strip by folding into a triangle shape, with end tab folded back, bottom tabs folded outward.

25. Position support triangle into the heel box . . . 

. . . attaching the bottom tabs to the box bottom.

26. Fold the remaining heel box edges into position and glue sides, then . . . 

. . . fold end "lid" into place with tabs on the inside of the box cavity, and glue tabs in place by holding and applying pressure from the outside.

27. Apply generous glue to the underside ("R" surface), position on tread, align shoe and heel edges as well as possible, and glue in place.

NOTE this process will also require time and patience for a neat and thorough join.

28. Use a tool such as the handle of this spatula tool to add forward curl to the tine edges of the fringe strip.

Also add some separate bend of flex to the individual tines.

29. Center fringe strip at shoe back, lining up the punch holes of each, and glue in place.

Wrap the side sections of fringe around the shoe, lining up the curve cut edge of shoe top.

30. Dry fit the upper assembly in the shoe to see how it should fit. Make sure the "R" right sides of shoe and upper corresponding, and paying particular attention . . . 

. . .  to how the front (and back respectively) of upper and shoe should line up. The upper should also be rotated or tipped forward/backward slightly as needed to more or less line up the side seams and perforations of each.

31. Remove the upper, apply adhesive to the inside near the shoe rim, then re-insert the upper and adjust to best positioning from step 30.

32. Assemble the tag layers. First, position and attach the contrast middle layer behind the front, with top edges even, side edges offset slightly, so that circle cuts allow the star cuts to show through to the back layer.

33. Attach the tag to the side tab with chain as shown, twine, or another fastener of your choice