Hat Colonial 3D Tri Corner Box

Iconic patriot head gear has eight-sided crown “dome” 

with round brim that is “curled” at side front edges 

to reach up and attach to dome sides. 

Edge trim adds accent, along with simple colored cockade. 

Octagonal short “base” can be inserted under the brim 

to convert the hat to a container, with cross straps 

that hook together to keep the base in place. 

Use as display for July Fourth decor, 

as a wreath or centerpiece decoration, or box “lid”. 

Measures approx. 4.25” front to back x 4.75” side to side 

at widest point x 1.625” tall at crown center when completed. 

(Size is coordinated to hang from the final ‘A’ letter box 

of “AMERICA 3D Letter Box Display” design.)

ASSEMBLY: 1. Identify and cut the shapes:

A brim   B crown wedges (8)

C brim under trim    D brim over trim (3)

E cockade scalloped disc, circle star

F cockade pleated "ribbon"

G box base main shape   H box base add-on wall strip

I box base octagon reinforcement  J cross straps

2. Prepare the brim shape by bending the opening

flanges back.

NOTE that the punch holes for brads or as guide marks

will orient toward the straight sides of the octagon

opening differently for center back and for sides.

Pointed at in this image are the octagon back edge

and the hole punch.

3. Further prepare the brim by rolling the three extensions

back for 2 inches or so next to the opening using

a dowel or other smooth rod tool. 

This will assist and allow

the brim to bend upward gently later in the assembly.

TAKE CARE not to apply bends - only curl.

Add the curl to each of the three "corners" or lobes,

keeping the curling tool parallel to the curved brim edge

where the punch hole is centered.

4. Add a corresponding back curl to the brim trim

at all three lobes.

5. Prepare to attach the brim under trim to

the FACE side (which will be the downward side -

or underbrim surface) by identifying the tiny cuts

that will indicate the center of each lobe.

Then apply glue to one section, and position so that

the guide cut aligns directly centered above

the punch hole, and with outer edges aligned,

and attach.

Repeat for the remaining two lobes, shaping the trim

to match the curl of the brim edge previously added.

6. Use the rod tool to add a little back curl to

the ends of the shorter three upper edge trim shapes.

Position and attach these trim shapes on

the backside or upper surface of the brim,

centered along the area between the lobes

(half of the trim shape is hidden by left hand here).

7. Immediately after the trim shapes are all in place,

assist the brim into its desired lobes-up configuration

then allow trim to dry so that shaping is "locked in".

8. Prepare the eight crown wedges by bending back

on all cross perforation lines and side tabs.

Also become familiar with the designated order of

the wedges which is essential for alignment of

brim punch holes with wedge punch holes later.

9. Begin to attach the first four wedges

(center back #1 and 2-4 as designated in cut file)

 by lining up two side by side with the second tier aligned,

straight side edge of the left shape overlapping

the tab of the right shape to perforation line.

Adjust up and down so that cross perf lines match up,

then join the seam.

10. Move downward to bend the bottom tier edges

into position with straight edge exactly along the tab

perf line, and join this seam segment. Then . . .

. . . move upward to bend, overlap, adjust

and join the top tiers in sequence until the whole

seam is completed.

11. Position and attach the third wedge in

the same manner, then the fourth to complete

a half dome.

12. Complete the second half dome with remaining

four wedges.

13. Prepare to join the halves by lining up and

overlapping the straight half edges over

the corresponding tabs, opposite. Then . . .

. . . apply fingertip pressure along top two segments

first, then work downward to opening edges to

align, adjust and join segments all along seams.

14. Position the dome over the top of the brim

(which has the FACE side downward) with the opening

tabs under/inside the dome.

Adjust the rotation of the dome so that each tab

aligns with a facet of the dome, then blue each

in place.

NOTE that it may be helpful with attaching each

segment of the dome-to-brim seam by inserting

finger into dome while also pressing from the outside

with a narrow flat/straight surface such as this

narrow Silhouette scrapper tool.

15. If preparing the tri-corner hat as a box,

prepare the cross straps by bending back at

end tab perforations, hooking the rounded ends,

then positioning at the side center octagon edges

inside the dome.

Align perf bend at brim/dome edge and glue in place.

17. Prepare the cockade "ribbon" shape by bending

perforations in accordion configuration as shown

(center pair of folds as "mountain" and outer pair

as "valley"). Fold the pleats flat and apply glue near

bottom edge between folds on front and back

to secure flat edge along bottom.

18. Assemble the medallion by layering and centering

the plain circle on top of the scalloped circle,

with the star on top.

19. Determine how you want the cockade to look

as far as star north/south orientation, then insert

the ribbon edges under the medallion approx. 

a generous 1/8" and glue to attach.

20. Bend each lobe up into final position to align

the brim and corresponding wedge holes, then

apply glue between around one of the holes

to attach the two surfaces. Insert and attach

decorative brad to adorn and assist the attachment.

21. Position and attach the cockade onto one of

the brim's sides as shown.

22. For the hat's box, prepare the main box base

and add-on walls shapes by bending back on all

perforation lines for wall segments, tabs, and

upper wall extensions.

23. Position the extension left straight short wall edge

at the main base's similar extension right end tab,

with edge overlapping the tab to align exactly

at perforation line, adjust top to bottom, then join seam.

25. Bend the octagon floor portion upward to allow

the wall strip to be formed into a ring to bring 

the free end tab to be inserted and attached under

the straight wall edge of the attached segment,

then join seam to complete walls ring.

26. Push the floor octagon down into place so that

edges slot into position along each of the tab perf lines.

Bend each tab inward and join to the floor underside.

Apply fingertip pressure from the inside to secure

each seam segment.

27. Position and attach the reinforcement shape

to the underside of box to conceal tab construction.

28. To close the box, insert box base into the underside

opening of tri-corner hat . . .

. . . then bend the cross straps

into position and hook to latch into place.