Frankie 3D Display Box

Not-too-scary Halloween decor doubles as a gift box 
with LID and BASE boxing compartments that 

fit snuggly together.  Built-up layers provide strength 

and substance, with separate “underside” layers with 

positioning guidance for boxing assemblies. 

Loads of details “bring Frankie to life”: 

shoe uppers and soles, shirt with batty buttons, 

craggy hands, highlighted eyes, head side bolts, 

flat-top hair, toothy grin, cheek ovals and scars. 

Measures approx. 8.25” tall x 4.25” wide with 1” deep boxing. 

INSTRUCTIONS: 1. Identify and cut the shapes:

A LID front panel shapes (3-4) to layer for thickness

B LID inner layer with guide marks

C LID boxing base shape

D LID boxing strips

E BASE bottom panel shapes (3-4) to layer for thickness

F BASE inner layer with guide marks

G BASE boxing base shape

H BASE boxing strips

Identify and cut the 'character' front panel shapes:

I pants decor shape    

J pants foundation layer extension (doesn't show)

K main shirt front   

L eyes white contrast panel with nose wedge contrast

M head foundation (doesn't show)

N arms, sleeves, shirt shoulders for left & right

O bat button shapes (2 buttons @ 4 each)

P shoes 'upper' foundation plus soles

Q face details: bolts and collars; cheeks, ear underlays

R flat top hair, long scar, eyebrows, eye blacks & whites,

small scar

S smile with teeth underlay

2. Identify the LID front panel shapes which have the 'L'

cut symbol; also identify the BASE shapes which are

reversed from LID with 'B'.

3. Position and attach the front panel shapes to create

a thick panel for box front, taking care to align ALL cut edges

as precisely as possible.

4. Identify the LID inner layer that has boxing shape

positioning guide marks offset approx. 1/4" in from edges.

Also NOTE that this shape is reversed from the outer layer.

Position this on the bottom of the front layer stack

with ALL edges lined up, and glue in place.

5. Immediately position a heavy flat object (such as

this planed wood plank, or a large book) over the top of the stack

to press flat while the glued-up stack is allowed to dry

completely (for a few hours). 

6. Repeat Steps 2-5 for the BASE build-up layers.

7. Position each of the four bat button shapes for a button

into a stack, and glue together, matching all cut edges

and hole openings, then press flat under a heavy object

until thoroughly dry. Complete two buttons.

8. Complete pre-assembly for components of the character

front decoration, and press under flat weight if possible:

A) layer optional eye highlight show-thru circles behind pupil;

B) position and attach bolt collar strips on top of bolt shapes;

C) position smile on top of the teeth/smile shapes;

D) position and attach sleeve and sleeve cap on top

of arm shapes for left and right assemblies

E position and attach shoe sole strips on bottom of shoes

Here are the components assembled:

9. Prepare the pants/foundation layer by

abutting the upper torso/head shape above the pants

shape with straight edges aligned, sides even,

and secure with small pieces of cello tape.

10. Prepare to position and attach the shirt main shape,

head foundation shapes with eye and nose contour

show-thru shapes . . .

. . . then position and attach the head shape with flat-top

and bolt shapes aligned with pants foundation,

position shirt shape below (with puzzle notch interlock)

and attach, then fit and attach eye show thru and nose

contrast in the recess that remains. Press under flat weight

while adhesive dries thoroughly.

11. Prepare to assemble the head:

A) attach hair where edges match

B) attach ear contrast shapes behind ear cutouts

C) attach left and right bolt assemblies

D) position and attach eyebrows, scars and smile.

Press under a flat weight while adhesive dries.

12. Position and attach shoe units onto assembly.

13. Position and attach the head assembly on top of

the body assembly layers where upper edges align, then . . .

. . . position and attach cheek ovals into recesses,

and eye units into eye socket recesses.

14. Position and attach character assembly

onto the LID stack front; press under weight until dry.

15. Become familiar with the identification system of

the boxing strips. Shapes have cut symbols of circle,

triangle or 'X' on end tabs and edge tabs to help identify

which strips are for LID boxing (single) 

or for BASE boxing (double), and . . .

. . . which strip ends join.

16. Prepare each strip by bending back top (LID) or

bottom (BASE) attachment flanges, end tabs, and

vertical perforations. It may be helpful to re-direct

the vertical bends so that the strips echo the boxing shape

edges, as shown below for LID.

This diagram shows the LID and BASE shapes with

the angle location where the strips will join, identified

by the symbol shapes cut into tabs.

NOTE that the L & B shapes are reversed to be

face down for assembly.

17. Position the lower/side boxing strip at the bottom edge

of the LID boxing shape, center edge along boxing segment,

then glue in place.

18. Position the next few tabs and edges around the feet

shaping edge so that strip segments align with edges,

and glue each in place. NOTE that there is a small

amount of allowance margin at main shape edge

that may need to be "averaged" or adjusted as strips

are positioned and attached.

 

19. Continue to position, align and glue tabs along edge,

applying fingertip pressure to firmly attach strip.

20. Position and attach the next strip (match symbols)

by overlapping straight edge over end tab to perforation line.

21. Continue to position and attach the boxing strip

around the top of boxing shape.

22. Position and attach the opposite side strip at end,

then position and attach around the side edge,

pausing before the final edges and tabs are in place . . .

. . . so that the final end tab can be slipped behind

the adjacent straight edge to align and join that seam,

while at the same time positioning final segments

to complete boxing attachment.

23. Position the boxing assembly at the backside of

the front built-up stack, using the guide assist

with placement, then attach in place.

(A flat weight such as a book placed on top of boxing

will assist with attachment.)

24. Repeat the boxing attachment of Steps 17-23

for the BASE.

25. Position and attach the bat buttons at shirt

center, tying with cord knot, bow and streamers

as desired, or . . . 

. . . insert a length of sheer ribbon front-to-back

through holes with trimmed tails as was done

for this sample, before attaching.

26. To close the box, fit together LID (outer walls)

and BASE . . .

. . . then slide completely together.

Here is the completed box.