Needles 'n' Knowledge: Skull 3D Realistic Form

Dimensional life-like skull composed of

upper skull and brad-hinged jaw.

Ear, eyes and nose depressions with

optional contrast overlay shapes add to the realism.

Sturdy construction means this decoration

will be around for many Halloween seasons.

Measures approx. 7.5" front to back x 5" top to bottom x 4" wide.

The tutorial model doesn't look that spooky - and

I don't mind that.

But you could customize it to make it spooky with darker

cardstock colorings, punch light holes in the eye "lining" shapes,

(or modify the eye and nose depressions, etc.) to let

battery-lit candle shine through.

Or add jewels and gems to glam it up like a sugar skull

ASSEMBLY: 1. Identify and cut the shapes:
A. top head main B top head add-on side
C head base D head base rim reinforcement
E & F front head left and right
G & H side head left and right
I & J ear depression insets with contrast shapes
K nose bridge
L & M eye depression insets with contrast shapes
N nose depression inset with contrast hape
O upper jaw with connected mouth rim
P mouth pallet inset Q pallet rim reinforcement
R cross post (interior reinforcement)
S lower jaw main
T & U lower jaw side add-ons left and right

2. Prepare the top head (A) and add-on (B) shapes

by bending back on all horizontal, vertical,

and tab edge perforations as shown.

3. Position the add-on tab next to the corresponding

side edge of the crown panel as shown, with crown

edge overlapped at tab to perf line, then glue in place.

4. Bend the side extension seam and corresponding

tab edges together to overlap to perf line,

and glue in place (two segments).

Complete these seam segments for both left

and right side extensions.

5. Identify the wedge tab near the crown panel

and bend the straight edge to overlap to the wedge

tab's perforation line to complete this seam

on both sides.

6. Complete the short seam at the back of
the crown panel.

7. Bend the back edges around to align segments,

then overlap straight edge to tab perforation line,

adjust, and complete the 3 segments of

the centerback seam, one segment at a time.

8. Flex the top head assembly to bring the crown

straight edges to overlap corresponding tab edges

to perf lines, and glue in place the 4-edge sequence.

9. Prepare the left (shown) and right front head

sections (E & F) by bending back on all vertical, horizontal,

and tab perf lines. Also gently bend back slightly

on the two diagonal perforation "shaping" lines.

10. Bend the upper vertical mid seam straight edge

to overlap the adjacent tab to perf line, and

glue in place. Repeat for both left & right shapes.

11. Join the left & right front head shapes together

at center top front seam line by overlapping right

over the corresponding tabs of left.

12.Position the top head assembly along the crown

and lower back side tabs as shown, with

straight edges overlapping corresponding

tabs to perforation lines of the other assembly

as shown . . .

. . . then glue edges in place to tabs,

working each segment one at a time.

13. Prepare the side head shapes (G & H) as shown

by bending back on all body and tab perf lines,

including gently bending slightly on short

connecting perf lines radiating from ear

depression opening.

14. Position and join the 2 seam segments

along the lower edges (this ridge helps

define the cheek contour).

15. Identify the right (shown) and left ear depression

insets by locating the tiny R or L symbol in

the forward (long) tab. Compare the depression

main panel with the corresponding opening in

the side head assembly.

16. Prepare the depression inset shapes (I & J)

by bending forward on all perforations except

for long tab perf which is bent back slightly,

as are upper edge connection tabs which are

bent back.

17. Bend the side wall extension around

the main depression polygon panel with

polygon panel overlapping the lower edge tabs,

and glue in place.

18. Position the inset under the side head opening

with the forward tab under the corresponding

opening edge. Align and attach the forward

tab first . . .

. . . then bend the remaining inset tab perf edges

into position at opening edges, adjust as needed,

then glue in place.

Complete for both right and left side head sections.

19. Position the side head section (left shown)

over the corresponding tabs of the head assembly,

align edges and tabs, and attach each,

one by one.

Repeat for the right side.

20. Prepare the nose bridge shape (K) by

bending back on all perforation lines except

bend the mid diagonal lines forward

(indicated by pointing finger).

21. Position bridge under the pointed edges

at the forward portion of front head,

and attach in place.

22. Overlap lower side straight edge of bridge
over corresponding tab of side head,
adjust and glue in place.
Repeat for both side tabs of bridge.

23. Prepare eye inset shapes (L & M) by bending

back outer edge tabs, and bending forward

the interior tabs and end connector tab as shown.

24. Form the depression shape by bringing
the tab end around platform panel to wrap
it around the top side edge of connected side wall
as shown.

25. Bend the platform shape into position,

adjust so that each side wall bend perf falls

at platform angles and edges align at

lower tab perf lines, and glue in place.

Repeat for both left and right eye insets.

26. Compare the completed eye insets with
the eye openings in the head assembly to
determine orientation (long tab edge corresponds
to the closest-to-center opening edge) . . .

. . . then place inset into head interior to position

behind opening edges, and glue each edge

to corresponding tab. NOTE: it may be advisable

to use a quick-grab adhesive on eye and nose

insets to prevent pushing through during

remainder of assembly or use.

Complete installation of both eye insets.

27. Prepare the upper jaw shape (O) by bending

back on all perforations and tabs.

(NOTE: some of the side perf lines may be bent

forward later in the assembly.)

28. Complete the upper edge seam by bending

the straight edge over the adjacent wedge tab

perf line, and glue in place. Complete both

left and right seams.

29. Bend the side extensions around into

position to overlap the mouth rim straight edges

over corresponding extension tabs - 2 seam

segments on right side, 3 segments on left -

and join in place.

30. Bend the 2 lower edge tabs on each just past

the mouth rim (both sides) up behind

upper jaw wall and attach in place.

NOTE: the final tab is NOT glued back,

but attached to head edge later.

31. Position the upper jaw assembly along lower

head assembly edge with straight edges

overlapping the corresponding tabs . . .

. . . and attach in place one by one.

Bend end tabs back . . .

. . . then tuck under corresponding head edges

and glue in place.

32. Prepare the nose depression inset by bending

top edge tabs back/outward, panel perf lines

and bottom edge tabs or panel forward.

33. Bend each edge wall extension around

the polygon back panel, then wrap the top tab around

the opposite top straight edge and glue in place.

Bend the polygon back panel into position and

attach in place.

34. Compare the completed nose depression
inset to the nose opening, then . . .

. . . apply glue to top edge tabs, and position

in place from under the nose opening

(from the inside of skull), adjust so that tab perf

lines up with opening edges, then glue in place.

(NOTE: it may be helpful to use a quick-grab

glue to nose and eye insets, such as Fabri-Tack.)

35. Prepare the base shape (C) by positioning

and attaching optional reinforcement rim (D)

on the face side, with corresponding edges

aligned.

36. Position the base shape at the bottom tabs

of the head assembly as shown, then

adjust and attach edges and tabs.

37. Prepare the mouth inset shape (P) by

bending edge tabs back, inner tabs and

end tab forward as shown.

38. Bend side extensions toward back to

overlap straight back edge over corresponding

wall tab, and join.

39. Bend the platform panel into position
at tab perf lines . . .

. . . and attach tabs to backside.

40. Position and attach optional reinforcement

rim (Q) shape at curved edge on backside.

41. Position the mouth inset under the mouth rim

with straight edges aligned at inset tab perf lines,

and attach in place.

42. Prepare the cross post shape (R) by bending

back on long perforation lines, and back

on end tabs.

43. Form the post into a triangular tube to

overlap long straight edge over opposite

tab perf line, and glue in place.

44. NOTE that the post triangle end has
a tall point that will correspond to
the tall direction of the cut opening. Then . . .

. . . identify the post LEFT end of the post
by locating the tiny 'L' symbol cut in the long tab.
Insert LEFT end through the right side
of head at triangle opening . . .

. . . across the head interior to insert through

backside of opposite left side opening . . .

. . . and through to position where tabs
can be bend back and attached in place.
Also attach right end tabs in similar manner.

45. Prepare the lower jaw main (S) and

right (T) and left (U) add-on segments by bending

back on all perforation lines and tabs,

except bend forward on perf lines noted

with asterisks in the image below.

NOTE: the small tab-like extensions at sides

of rim narrow panels should not be bent.

46. Position add-ons and join tabs to underside
of main lower jaw shape.

47. Join extension first side seams to adjacent

tabs, both lower segment shown here . . .

. . . and upper (contour) short segments,

bending edge and tab perf into alignment.

NOTE: during this process, make sure that

the attached tab-like extensions underlap

the adjacent "rim" section.

48. Continue to position and join the two seam

segments of the next seams . . .

. . . and finally the center front seam
in the same manner.

49. Test form the mouth rim by bending the left

center front extension to the jaw inside

to a perpendicular position, then unfold. . .

. . . to apply adhesive to the underside of
the flange along a 1/4" to 3/8" margin at bottom,
re-fold to jaw inside and glue flange bottom edge
to backside of jaw.