Sunday, March 3, 2019

Leprechaun Torso 3D Block

Multi-facet shaped box has edge that forms around 
the leprechaun body, arms, beard and hat to create a whimsical 
and unique display “block” for St. Patrick’s 
Day decor. Build the box “lid” and “base”, fit together, 
then add decorative shapes, including a nose circle 
cut out for optional 1/2” wooden “plug” mushroom 
to add even more dimension. 
Measures approx. 7.125” wide x 8.25” tall x 
1.75” deep when assembled. 

ASSEMBLY: 1. Identify and cut the shapes:
A Lid front panel (with nose hole)
B Lid top boxing strip
C Lid right side boxing strip
D Lid left side boxing strip
E Lid bottom boxing strip
F Base back panel
G Base top boxing strip
H Base right side boxing strip
I Base left side boxing strip
J Base bottom boxing strip
L Hat area cross brace
M Neck area cross brace
N Upper (triangle) support strip
O Mid (square) support strip
P* jacket accent   Q* head/hands accent
R hat band strip   S hat main base
T hat band base  U hat band contrast  V Hat buckle
W beard shape   X eye circles
(Wood mushroom plug NOSE shown below eyes:
if preferred cut nose circle(s) in place of plug)
Z shamrock    Y belt
*these shapes have been modified in final version
2.  Begin the leprechaun front panel assembly
by layering hat band contrast onto base,
with buckle on top, and attaching all together.
Position and attach belt and shamrock using
hole punch as a guide.
3. Continue assembly by positioning and attaching 
hat brim over lower portion of hat,
shirt over lower portion of body so that sleeve
end "straight edge" aligns at similar shape at hand.
4. Complete assembly by positioning and attaching
hat band over hat crown so that buckle is above brim.
Position beard shape so that top straight edges
align, and so that head/face edges are concealed.
NOTE: if using liquid adhesive, consider placing
the assemblies under flat weights to press flat
until glue is completely dry, to avoid warping or curling.
5. Locate the cut symbols in the end tabs or
near ends of each of boxing strips for LID and
BASE. NOTE that the base symbols are "double" symbols.
Refer to this illustration to see where the boxing strip
ends will join, according to the symbols on each strip.


Also NOTE that there is a tiny 'T' cut into the TOP
panel's flange as shown here.
6. Prepare the boxing strips for LID and BASE
by bending back on all segment ends and flanges.
Become familiar with the symbols cut into end tabs
and flanges. Here is the right end of TOP strip
with the single circle punch cut into top flange,
which corresponds with . . . 
. . . the end tab/flange of the right side boxing strip
flange which has a single circle symbol.
(BASE boxing strips will follow similar, mirror
image pattern with double symbols.)
7. Arrange the boxing strips around the LID front
panel, re-bending the strip perforations to follow
the shape angles (inward or outward).
Coordinating the symbols at strip ends will help
to get the strips in the correct position.
With the LID face up as shown, the boxing strips
should have the attachment flanges at top,
just as if the front panel could be placed on
top of them to assemble the LID.
(BASE will follow similar pattern, but will be
appropriately arranged in mirror image as designed.)
8. Start boxing assembly at TOP of front panel,
positioning the 'T' flange next to the top edge
of panel, then overlap panel's straight edge over
flange to align at perf line, then adjust for
end to end alignment, and glue in place.
9. Bend the next segments of boxing into position
along the front panel edges, overlap and align
edges with flange perf edges, and glue each in place.
Work for more accurate alignment as each is joined.
10. Repeat step 9 for the opposite side segments
of hat area.
11. Position the right side boxing strip end flange
next to the end of TOP strip, overlap straight edge
over end flange, adjust for ends alignment, and join.
12. Bend the boxing strip into position to overlap
panel straight edge to corresponding flange perf edge,
and join. Continue in the same fashion to position,
align/adjust and join each segment flange in place
along the front panel edge. Align and join all segments
of the right side strip.
13. Position and join the bottom boxing strip end
to bottom end of right side boxing strip,
then continue in same manner to position and join
segments to corresponding edges of front panel.
14. Join the left side strip and join in place in same manner,
pausing when the final two segments need to be joined . . .
. . . to apply adhesive to the final end flange tab
so that the final segments AND end flange can
be positioned and join in the same step.
15. Repeat steps 8-14 to prepare BASE in same way.
16. Prepare the neck area cross brace by bending
end flanges back.
DO NOT bend back end flanges 
of longer hat brace strip.
16. Position neck cross brace inside the BASE
across the narrowest expanse at neck angles.
Attach each end tab to walls to help stabilize
the base shape. 
17. Position the hat cross brace in similar manner,
except the end tabs can simply be laid on top of
lower hat angle, perforations aligned at angle,
and glued in place.
18. Prepare the interior triangle (bottom) and
square supports by bending back on all segment
ends and end flange perforations, and bend
upper and lower edge tabs forward, as shown.
19. Form the supports into rings to join end 
edges and flanges.
20. Apply glue to bottom tabs of each support
(in turn), then position each, centered, as shown here:
triangle support in hat area, square support in
body area. Apply pressure to secure in place.
21. Position the leprechaun head/body assembly
on the front panel, with offset edges all around,
and with nose circle cutouts aligned as indicated
and attach in place.
22. Position the hat assembly above the head
with straight edges abutted together,
and attach in place.
23. Glue eye circles into eye recesses.
Position, insert and glue in place the painted
nose mushroom button. Or, alternately, position
and attach the paper nose circle or stack of circles
over the hole.
24. Apply glue to the support top tabs, and . . . 
. . . to the lower margin along BASE boxing strips
all around, then . . . 
. . . position and slide the LID onto the BASE.
Quickly apply pressure all around - and especially
at inward angles - to make sure
that the LID shape conforms to the stabilized BASE
shape. Use heavy objects placed next to and touching
the boxing strips in strategic positions as necessary
to assist with this until the glue is dry.
Here is the completed leprechaun torso box.
(Pssst: here's a secret --
the leprechaun torso box fits very neatly on top
of the "Irish Blessings Blocks Ensemble"
for an extra special combination display!)

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