appearance of thick walls, with tall decorative uprights
composed of
built-up layers supporting a hexagon
tube-wrapped 3/4" diam. dowel handle.
Interior cross-wall partition creates two compartments.
Add offset panels as decoration, then tie
decorative
tag to the handle.
Sized to coordinate with specialty printed panels
(shown
here with Graphic45's
“Place In Time February Cut-Aparts”),
“Place In Time February Cut-Aparts”),
including extra
shapes to trace and prepare
“chipboard” built-up base shape embellishments.
Measures approx. 7.75” tall x 8” long x 4.25” wide.
ASSEMBLY: 1. Identify and cut the shapes:
A box front with attached bottom panel
B box back C box sides (2)
D handle tube E partition panel (*8 layers)
F front, back accent panel overlays (2)
G side accent panel overlays (2)
H box bottom reinforcement panel (1 or more)
I upright panels with "inward" build up layers (2 sets of 7* ea.)
J upright panels outward "face" shapes (2)
K upright offset accent overlays (2)
*see steps 2 & 3 for information to determine
exact quantity of layers required
2. Each upright will consist of multiple layers of card stock
of the hex post hole shape plus single non-hex hole
shape outward "face" shape
that are built up to match the width of the slot
on main hull front and back where they will
eventually be inserted.
To determine build up layers quantity to cut,
cut approx. 8 of the upright shapes
(simulated here to include the 7 hex hole shapes
plus single non-hole face shape),
and layer (but don't glue yet), and stack.
Test this quantity to see if the stack will fit comfortably
through the slot cut out of the front/back panels.
If too loose, add an additional layer, test, then
finalize the quantity needed, and cut out.
If too tight, remove a layer, test, etc.
shape, by layering 8 rectangles, then . . .
. . . test for fit by inserting the stack into the slot
of the upright shape. Add or subtract layers as needed
to determine the final count.
4. This tote project was specifically designed
to use the various panel shapes of the Graphic45
printed panel card stock mentioned in the introduction.
Shown here are the add-on panels and embellishments
used in the final project, together with their stacked
duplicate shapes or accent panel underlays, etc.,
provided just for information and inspiration.
5. Layer and attach the upright layers into a stack
as determined in step 2,
but NOT including the non-hole face shape
(which is added later in the assembly process).
Take extra care to make sure that all cut edges
are aligned as precisely as possible,
particularly at the hex hole opening and slot edges.
Immediately press the glued-up stack under a flat weight
or heavy object such as the fabric-covered,
re-purposed weight machine bar shown here
(the upright requires two bars placed side by side)
until the glue is completely dried.
Pressing with weights will help minimize warping
or curling of the glued-up shape when using liquid glue.
This may require several hours.
Also NOTE that the 8 or so layers required for
the upright thickness may need to be stacked
in a couple of sessions, allowing the first 5-6 stacked
shapes to dry, before attaching remainder.
6. Layer the partition wall in similar manner,
taking care that all edges are aligned
as precisely as possible, stacking and joining
part, allowing stack to dry, then attaching remainder.
Use a flat weight to press the partition shape
until it is fully dried, for several hours.
7. Prepare the back panel by bending on the perforation
lines as shown, all back (mountain folds) except
for the inner flange tabs shown here at top.
halfway down the panel. These will be used toward
the end of the assembly as a way to guide
the final positioning of the flange tab edge as walls
are completed.
noting that the perforation line indicated is
the connection of the front to the bottom panel.
10. Prepare the side panels in similar manner,
bending back at side flanges and interior (rim)
perforation lines, and forward at inward flange perf line.
11. Assemble the box base by aligning and joining
the front/bottom with the back panel at bottom flange,
then adding the side panels to connect with
the bottom panel at center.
12. For strength and a little extra weight,
position bottom separate reinforcement panel
onto the bottom of the box assembly, within
the perforation lines or panel edges that
define the box bottom. (Add additional layers
as desired and cut.) Press with flat weights
until the panel(s) adhesive is completely dry.
13. Position and attach the accent panels
to the outer surfaces of front, back and side walls.
14. Bend the walls back to overlap straight edge
of front/back panel over adjacent flange, adjust,
and complete side seam.
Repeat for 3 remaining corners.
14. Prepare the handle post wrap shape by
bending back on the long perforation lines,
and at the end tab lines.
the straight edge over the opposite flange to
perforation lines and glue in place.
flattening out the tube shape, or by wrapping
it around the 3/4" dowel and forcing the edge
inward to overlap the flange to perf line.
16. Prepare to measure the dowel piece needed
as handle insert, by bending tabs forward,
sliding dowel cut end to be even at top, then . . .
. . . mark the dowel length even with the shaft
of tube wrap, with bottom tabs bent out of the way.
Cut the dowel as marked, with exact perpendicular cut.
17. Insert end tabs of first post end through hex hole
front inside toward outside . . .
to enclose the post tabs, and glue in place.
Use flat weights to press this attachment until dry.
19. Repeat the process to insert the second end
of post tabs through second upright stack,
bend and glue tabs to backside, position and
attach second "face" shape over the assembly
and glue in place, using flat weights to assist
drying process.
19. Bend front and back box walls toward center,
then complete a "test run" or insertion by
carefully inserting bottoms of upright/handle assembly
into the rim slots, and . . .
. . . slide down fully into position where the upright
straight bottom edges seat at box bottom.
Lightly mark the wall height onto the face of
each upright. This mark will indicate the level
below which adhesive can be applied.
20. Remove uprights, apply glue tape or other adhesive,
then re-insert and attach outer wall backsides to
respective front or back upright.
21. Apply adhesive to the bottom and ends of
the built-up partition wall.
Position the partition inside the middle of box,
and insert first end into the upright slot, with bottom
flush against box inside bottom surface. Then . . .
upright slot. Apply pressure to attach the partition in place.
22. Bend the front and back interior walls down
into final position, with the flange edges aligned
at the guide mark perforation line
(NOTE there is a step-down transition between
the thickness of the uprights and main wall;
attach the flange to each as neatly as possible.)
When the walls are in correct position, the rim
portion should be at a ninety-degree angle
to the outer wall.
23. Prepare the bend the side wall inward by
first applying a dab of glue at "inward triangle"
portion of end of front and back wall rims, and . . .
Then bend the side walls inward as with
the front and back walls, positioning flange edge
at perf guide lines, with side wall rims overlapping
the ends of adjacent rims to form a miter "seam".
Apply pressure to join where glue was applied.
Repeat for second wall attachment.
24. Position the upright overlay accent panel
to attach it to both the top portion of upright
and to front or back wall, with offset margin all around.
25. Complete additional decoration and embellishment
of the tote, including placing of the front and back
rectangular panels as shown here.
Here is the completed tote with minimal
accent panels in place.
The following four images will show how the model
was completed using the Graphic45 "February"
card stock print panels.
Here is the front, with umbrella girl panel, built-up
colonial couple as a circle and built-up base.
panel, tete-a-tete couple panel and trimmed February oval.
built-up mini hearts and swirl tag with
built up cupid heart add-on.
The completed tote box with Graphic45 panels.
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