Sunday, July 31, 2016

Whale 3d Hinged Box Tutorial

Smiley mammal "fish" is composed of "base" 
(includes lower body, tail extension with accent overlay, 
"striped" tummy that wraps around sides and lower front 
with optional mouth and teeth shapes) and "lid" 
(includes upper head with splash side cutouts, 
top spout swirl spray, back end tab). 
Lid and base attach to each other 
with black regular size brads as eyes. 
(Inner tabbed strip reinforces across the body at hinge position.)  
To close, pivot the lid toward back and 
fit tab into slot above tail. 
Measures approx. 3.125" wide x 6.5" long (tail tips) 
x 3.5" (spout top). 

ASSEMBLY: 1. Identify and cut the shapes:
A upper body "lid"    B two part "splash" backers
C spout (l & r) base and swirls
D lower body "base"
E "stripe" belly accent    F mouth & teeth accents
G upper tail assembly with fluke accent
H inner front hinge support
2. Prepare the base lower body shape by bending
tabs and panels back, tail end forward slightly.
3. Prepare upper body lid by bending back
tabs and panels, back tab up slightly.
4. Prepare the upper tail panel by bending tab
 back slightly, all other perf lines bend forward .
5. Assembly the lower body tail seams by bending
to bring the first side segment edge to overlap
the corresponding tab perforation line and
attach in place.
Continue to bend, align and attach the remaining
two segments on the first tail side,
then repeat for the second tail side.
6. Complete the front head seams for the base
in similar fashion, bending the shape to bring
together the straight edge segment to overlap
the corresponding tab perforation line,
align and attach.
Complete both side head seams.
7. Prepare the underbelly "stripe" accent
by bending back on the three perforation lines.
8. Center and attach the teeth accent shape
along the top of the mount accent shape.
9. Position and attach the teeth/mouth unit
along the top of the belly accent shape.
10. Apply glue to the whole backside
of the belly accent unit, then position it on 
the base assembly with cross bend lined up 
at the similar angle of the base. 
Bend front and side panels to touch 
and attach to the base.
NOTE that the brad hinge holes on the
sides of base should remain exposed.
11. Position the tail fluke accent onto the
upper tail panel, with stem end edge at panel bend,
and edges slightly offset, and attach in place.
NOTE: a second fluke accent shape can be cut
and attached to the corresponding position on the
tail end of the base, if desired.
12. Position the upper tail panel over the backside
of the base tail end, and glue tail in position with
edges that match up carefully aligned.
13. Bend the tail panel into position to line up
the segment edges, one by one, to overlap
and align with the corresponding perf lines
of the base tail form.
Complete tail seams for both sides. 
NOTE that it may help to reach the seams
and provide a "press against" surface by inserting
a flat tool such as the blade end of this spatula tool.
14. Bend the rim tabs - one at each of four edges - 
to the inside of the base "box", and glue in place.
NOTE it may be helpful to place the edge being
glued flat on a smooth surface and apply
finger pressure all along the tab flange until
it is securely in place.
15. To provide contrast for the "splash" cutouts on the
sides of head, layer the two part "liners" for
left and right.
NOTE if you prefer that both splashes show through
as a single contrast color, omit the smaller shape.
16. Apply adhesive around the splash cutouts
in the approximate size of the liners . . .
. . . then position the liners behind the cutouts
so that the divider edge between the two colors
is hidden in the bridge between cutouts,
and attach in place.
Complete both left and right splash accents.
This is how the splash areas will look with
liners in position,
17. Complete head front side seams in the same manner
as other seams have been completed.
18. Complete the back side seams of head lid.
19. Layer the spout accent swirls, centered within
offset, as shown, base cut of swirls at
bottom tab perforation line.
20. Bend end tabs outward, then position the
two bases back to back, align edges carefully,
and attach together.
21. Insert the tab end of spout through the head
center top slot, push through just to tab perf line,
bend outward on the inside and glue to the
underside of the head "roof".
22. Position the head over the body so that
hinge punch holes align . . .
. . . then insert a decorative brad eye
through each side.
On the inside, bend the prongs back securely.
23. Prepare the hinge support strip as shown . . .
. . . then apply adhesive to one of the inner panel
backsides, bend and apply pressure.
Take care that edge flange tabs remain free.
24. Apply adhesive to the underside of the tabs
then insert into the base and attach just behind
(toward tail)
the brad attachment area, attach to the inside
surface of the base, and hold in place until secure.
This reinforcement keeps the whale body from
"squashing" when being held and opened.
Here you can see how the hinge works 
to open . . .
. . . and close the whale box.
To secure in closed position, insert the tab
into the slot.
Here is the completed whale box.
To further enhance his "charm", consider
adding a highlight "tutti dot" to eye brad heads 
with a stylus or other fine point too
l such as wooden mean skewer.

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