Pilgrim Fig 3D Box Stack

 

Six rectangular boxes and one angled “box" evoke 
a stylized Pilgrim gent for Thanksgiving decorating. 

Interior support “struts” give them structure so 

they won’t collapse downward. 

Back closures of bottom compartments are tuck-in tabs 

so that small treats or goodies can be added if desired – 

to convert him into a unique gift box. 

(Alternative “suit” box shapes included for 

glued-closed assembly.) 

Ensemble measures approx. 3.75” wide x 3.75” deep (at bottom) 

x 7.75” tall. 

ASSEMBLY: 1. Identify and cut the shapes:

A body box 1 (bottom) with interior strut support strip

B body box 2 (middle) with interior strut support strip

C body box 3 (top) with interior strut support strip

D collar thin box with interior support strip

E neckband box

F face/head box    G face overlay with eye cutouts

H eye contrast oval insert

I face/head box interlocking interior supports

J hat brim box with interior support strip

K hat crown shaped box   

L buckle (3 layers for thickness)

2. Complete advanced buckle assembly by layering

and gluing together the buckle shapes in a stack,

taking care that all cut edges are lined up precisely.

Press under a heavy flat weight until thoroughly dry.

3. All body boxes are assembled in similar manner

as box 3, which is demonstrated here. All body boxes

and strut strips include an identifying and pairing

number cut into side tab or panel.

Prepare box hull by bending back on all perforation

lines for panels, flaps, tabs.

Also prepare the "container" strut strip by bending back

on center perforations, and forward 

at tabs and strip end tabs.

4. Form the body shape into a tube to bring straight

side edge around to overlap opposite side tab perf

line, adjust for top to bottom alignment, then join seam.

NOTE that the symmetry of this cut shape allow it

to be flattened onto work surface so that finger tip

pressure can easily be applied along the seam.

5. At the end opposite to the opening flap,

apply glue to the small side tabs, and to the face

of the end panel flange, then tuck tab into

the box and glue closed.

NOTE that to assist with these seams, it may be

possible for smaller size boxes to insert finger tips

inside box to apply pressure. Or, use the end of an

unsharpened pencil (or new eraser end) to insert

to apply pressure to tabs until secure.

6. For the sample being assembled in this tutorial,

the "contained" style struts. Here, its final positioning

on the interior of box is demonstrated where it can

be more easily seen.

Apply glue to the backside of strip between perforations,

and also on ends before perforations, and on

bottom faces of tabs. Then . . .

. . . insert the strut strip into the box with tabs

toward bottom (flap-attached face) and attach

in place.

Apply pressure to attach all glue-applied components.

7. (View steps 10-12 for similar assembly of collar box.)

If using the non-opening box variation, the struts

are configured into a square frame as shown here.

Bend on perforations, then form into frame and

attach end tab. Follow similar steps to apply glue

to tabs then insert strut into box, center and adjust,

then apply fingertip pressure to tabs that

can be reached. 

8. For container box style, bend side tabs inward

and then tuck flap in to close box.

(For alternative design, apply glue and tuck tab

inside to close and seal seams.)

9. Prepare he collar box in similar fashion to body

boxes. Also . . .

. . . prepare interior strut support strip by bending

back on all short vertical perf lines, bending 

tabs forward. 

10. Form the strut into a square frame to

join end seam.

11. Bend side panels back and join corner seams.

12. Apply glue to bottom face of strut frame tabs,

then insert and center in "tray" before . . .

. . . bending side flanges inward and top wall downward,

tucking end flange tab down into position to close box.

13. Prepare the neckband box by carefully bending

back the center "cavity" walls along smallest

perforation lines square. 

Then bend back on all

remaining perforation lines for panels, walls, tabs

and end flange.

14. Form the neckband shape into a tube to bring straight

side edge around to overlap opposite side tab perf

line, adjust for top to bottom alignment, then join seam.

Flatten and press along seam to secure it.

15. Bend side flanges in, apply adhesive to upward

faces, and to end face of tab, then close top and

tuck in end tab to seam and close the box.

16. Prepare the head/face box in usual manner, then . . .

. . . position and attach the face plate overlay

onto the panel with eye contrast oval cutout,

taking care that edges align precisely with perf lines.

17. On the backside of the box shape, position

and attach contrast eye oval into the recess.

18. Bend walls into position to join four corner seams.

19. Prepare the interior support by interlocking

the two X struts and center slots.

20. Insert the X strut assembly into the box's

interior with wall ends reaching into box corners

as shown. 

Then bend side flanges inward. Apply glue to

flanges upward face, lid end flange, and bend

lid into position to tuck end flange in behind wall.

Apply pressure to attach seams.

21. Prepare the pyramidal hat crown shape by bending

back on all perforation lines for panels and tabs.

22. Form the crown into a pyramid tube to bring

straight side edge around to cross side flange,

opposite, to perforation line and glue side seam.

Flatten to apply fingertip pressure along seam.

23. Bend "lid" panel down and tabs inward, then

position and attach "lid" in place.

Invert on work surface to insert finger tip to apply

pressure to "lid" seams all around.

24. Bend bottom tabs inward and apply glue, then

bend bottom frame panel into position to join in place.

Use cut out opening to reach finger tips inside to

apply pressure all around.

FINAL ASSEMBLY

24. Arrange the body boxes into a centered stack,

bottom to top in descending sizes.

Apply quick grab glue such as "Fabri-Tack" to

underside of smaller box being attached, then

position and center it onto larger box, checking

the exposed margin all around for evenness.

Hold in place until secure.

25. Repeat for the smallest, top body box.

NOTE that for the "container" style box, the finger tip

cut out for all three in the stack should be aligned

together at the "back" of the stack.

26. Apply glue to bottom of head box, then insert

it into the interior recess of the neckband box.

Push fully down, then hold in place until secure.

27. Position and attach head/neckband box assembly,

centered onto top of thin collar box, with even margins

all around.

28. Position head/neckband/collar assembly, centered, 

on top of body stack (apply glue to top of box #3)

and attach in place. Be sure to orient the face panel

side of assembly toward the "front", opposite

finger tabs, if using the container style body boxes.

29. Position crown box on top of thin hat brim

box, centered with even margins. Then . . .

. . . position hat assembly onto top of head box

and hold until securely glued in place.

30. Position buckle on front of hat and attach.

If desired, prepare a small bowtie bow and attach

at center of neckband/collar boxes where they join.

Here is the completed Pilgrim man figure decoration.

31. To fill and re-close body boxes, use thumb cutouts

to open back panels.

A female Pilgrim Lady Stack box decoration

is available as a companion design.