Friday, June 24, 2016

Chunky 3d Star Assembly Guide

Build five simple star point boxes 
(open bottomed with glued-on cover), 
add overlay panels for "flag" stars & stripes configuration 
(or use whole point shape for all overlays), 
then "lace" the points together for a display star 
for a patriotic event or decor. 
Star measures approx. 10.5"  wide x 10" tall x 1.5" deep. 

ASSEMBLY: 1. Identify and cut the shapes:
A star point boxing (side) right (5)
B star point boxing (side) left (5)
C star point front (5)   D interior support "tube" (5)
E star point back (5)
F star front accent shapes
(grouped to cut together as svg file opens to 
assist with cutting as "continuous" pattern;
see Step 12)

 (following steps 1-11)
2. Prepare the left and right boxing - or side panels -
of star point by bending side flange tabs back,
top or bottom tabs back, and bend at the middle
cross perforation line, as shown.
3. Join the left and right sections by overlapping
the plain top edge of the right strip over the top tab
perforation line of the left section, adjust and
glue seam.
4. Complete the bottom point seam in similar fashion
by overlapping the left bottom plain edge over
the right bottom tab to perforation line, adjust,
and glue seam.
5. Push the point boxing into relatively final shape,
with top flange tabs bent at right angles to walls,
and apply glue to the tabs. Take care to add glue
to the very tips of the points, especially top & bottom.
6. Position point front over the tabs, line up all
edges with side perforation corners, and glue in place.
Take care that lacing punch holes lines up - 
here and throughout the assembly.
NOTE: adjust the shape of the point boxing (sides)
by pushing sides inward or outward for a precise
match to the front point shape.
During the gluing process, turn the point face down
on flat surface, and insert fingertips pressure . . . 
. . . or tool pressure from along each tab to assist with
secure joining.
7. Prepare the interior support strip by bending
back on all perforation lines.
8. Shape the strip into a "tube" form to bring
the plain straight side edge to overlap the
opposite side tab to perf line, adjust top and
bottom so that edges match, and glue seam.
9. Apply adhesive to the wall corners, and to the
top cut edges . . .
. . . flatten the tube to fit into the point's 
back opening . . .
. . . insert completely until top is flush
with the backside of the point's front shape,
then . . .
. . . open tube into its roughly square form
with corners touching upper and lower
angled wall backsides.
Before glue grabs, adjust the position or
shape of the support "tube" to ensure
that the punched lacing holes will be
free from interference.
Lift the back tabs and apply a few dabs of
glue to back corners of support tube,
then replace tabs and apply pressure
to join to top of support.
(NOTE: Continue onto the next step
before glue dries completely.)
10. Position point back over the opening,
align edges with boxing perforation edges,
making adjustments to point shape as necessary
for precise match, and glue in place.
As part of the gluing process, it may be helpful
to insert a flat tool such as this spatula
behind the back point shape and the tab to which
it is attaching in order to apply finger pressure
from the outside, for a secure join all around.
11. Apply glue to the back shape "frame",
then position, adjust and attach the back cover shape.
12. Position and attach the accent shapes
to each point front.
If your design includes the stars & stripes coloration,
it may be helpful to place the points into their final
positions, then lay the accent shapes on top.
PATTERN MATCHING: To make the stripes panels
and/or the stars panels print patterns match up
as if cut "whole", leave the shapes from the cut file
grouped together with arranging on cutting mat
prior to cutting. Cut, then remove shapes carefully
in order to be able to position on the appropriate point.
Position and attach each accent front panel
onto assigned point box.
13. LACING: for inner holes, cut a 1 yard length of twine.
For outer holes, cut 1 1/2 yard length.
Anchor twine end (1.5-2 inch tail) on backside 
of first point box with temp tape such as masking tape.
Thread lead end onto a long darning needle or
4" doll needle (shown here).
Insert needle through inner end hole on back,
push through the interior of the box to exit
through corresponding hole on the front of box.
(NOTE this may be a patience-requiring process;
use the side wall hole punches to view & adjust the
needle point position so it can exit the opposite hole.)
Pull twine through completely.
14. Position second point box next to first.
Insert needle and twine through adjacent hole,
through interior and out the back at corresponding
15. Move to the closest back hole across the point
of second point, insert needle through to front,
and pull twine through completely.
As indicated by pointing finger, the stitch that
should be produced by the lacing travels perpendicular
 across the edges of the two touching point boxes.
16. Continue this stitch lacing around the inner
point holes to connect the remaining three points.
Un-tape lead end, tie off ends in a secure knot,
and trim ends short.
17. Secure the touching panels of all points
by applying quick-grab glue between, then
applying pressure until secure.
18. Repeat the lacing process to add the lacing
stitches at the outer pairs of holes.
Tie off on the back
Here is  the completed chunky star.

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