Friday, January 18, 2019

Snowflake 3D Luminary Box with Handle

Rustic box has outer panels that are layered to be thick 
for strength (and weight) with a front panel that has 
a snowflake cut-out. 
Top box rim is .375” deep to simulate wooden walls. 
U-shaped “decoration only” handle can be pivoted 
with ends that fit into side holes 
with turned-look handle that is built up in offset layers
yo simulate dimensional “turned” spool shape. 
Luminary measures approx. 6” tall x 3.75” wide 
x 3.75” deep without handle. 

ASSEMBLY: 1. Identify and cut the shapes:
A hull front (with snowflake cut out), side
& bottom
B hull back & side
C front contrast overlay (4 for build up thickness)
D, E & F sides and back contrast overlays
(4 each for build up thickness)
G handle base (6-8 for build up thickness)
H turned handle base (2)
I turned handle overlay layers #2 (2 sets of 3)
J turned handle overlay layers #3 (2 sets of 3)
K turned handle overlay layers #4 (2 sets of 3)
2. Prepare the hull shapes by bending back on
all perforation lines, except upper edge tabs, which
bend forward as "valley" folds.
3. Position and join the hull shapes at center seamline,
taking care to adjust top and bottom of straight edge
and tab at perforation line.
4. Layer the front, back and side panels for thickness
build up, and glue each into a stack, taking care to
align all cut edges as precisely as possible.
Immediately press each glued-up stack under a flat heavy
weight such as this fabric-covered repurposed free weight
bar, or a thick book or something similar, and leaving
in place until the stack is completely dry. This may
require several hours or overnight, and is critical to
assist the shape to remain flat, without curling or warping.
5. Position and attach in place each glued-up stack
onto the appropriate hull panel, with slight offset margin
all around (snowflake window should align exactly).
Position heavy flat weight on top of each panel again
to assist proper adhesion until thoroughly dried as before.
6. Form the hull into a tube to bring plain straight edge
to overlap opposite flange tab to perforation line,
and join second side seam. NOTE that the hull's
symmetry will allow it to be laid flat to apply fingertip
pressure along the seam.
7. Identify the dashed guide line inside the hull walls . . .
. . . which will assist with positioning of the top rim
end fold edge. Apply adhesive to the end flange
of SIDE walls, then . . .
. . . bend inward until the fold is aligned at guide mark . . .
. . . and the two perforation lines form a rim that is
perpendicular rim edge. Press the end flange until
fully secure.
Top rim edges should be level with each other
and at a right angle to hull walls.
8. Prepare the repeat the rim wrap process with
front and back wall tops by applying glue to backsides
of end flange tabs, and also adding a dab of glue at
ends of previously-positioned rims where the miter
edge will overlap (on both ends of both rims) . . .
. . . then bend the rim flange to inside of hulls
to attach end tab perforation line at guideline, as
before. As this is completed, the angled ends cut edges
will overlap side wall rims to form the miter seam.
9. At bottom of hull, bend flange tabs inward,
bend hull bottom panel into position, square up
edges with walls, then glue in place.
10. Layer and glue together the handle layers,
aligning all cut edges precisely. Immediately
press under a heavy flat weight until completely dried.
11. Position and attach the turned handle overlay
to front and back faces of handle assembly.
Press under flat weight until dry.
12. Layer and attach handle layers 2, 3 & 4 for build up
thickness; press until dry.
13. Position and attach layer #3, then . . . 
. . . layer #4 onto layer #2 to complete an assembly 
for front & back of handle; press until dry.
14. Position and attach each overlay assembly
onto front or back handle assembly. Press.
15. Carefully insert bottom handle end into side wall
slot, then . . .
. . . flex as slightly as possible to swing the handle
into position to insert the opposite end into its slot.
Here is the completed luminary box.
(Continue further for final anchoring steps
to ensure handles can stay in upright position.)

16. Prepare the handle lock shapes by bending back
the interior "window" opening tabs.
Locks are designed to fit over the handle ends
as shown here, but wait until handle is in place
before attaching them.
17. With handle ends inserted, apply glue to
backside surfaces, then position over the end
of handle inside of box. Reposition the handle into
upright position, then press lock in place, adhering
the tabs to handle surfaces, and the rounded base
to inside wall of hull.
Here is the model luminary with an LED
short candle placed inside.


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