Santa Gift Card Box

Festive Santa Claus head is layered together 

and attached to the LID front of a low-relief gift card box. 

Make Santa’s features even more dimensional 

by adding a painted .375” diameter wood hole 

“button” plug in the hole cut out on front layers. 

(Optional round shape to substitute and cover 

the holes is also included.) 

Box measures approx. 5.5" tall x 4.25" wide x .875" deep

to hold a standard gift card. 

ASSEMBLY: 1. Identify and cut the shapes

A head base shapes (2-3 for thickness and strength)

B head base front layer (with eye contrast window)

C eye contrast rectangle

D face   E hat   F hat fur strip and tassel ball

G beard   H mustache

I LID top main shape    J LID boxing strips (2)

K LID interior panel

L BASE bottom main shape    

M BASE boxing strips (2)

N BASE interior panel

Also shown near shapes E & D is the painted

wood button "cover" for dimensional nose.

(NOTE that a circle shape is included in the file

to substitute for the wood button.)

2. Layer and glue together the head base shapes,

taking care to align ALL cut edges as precisely as

possible, paying particular attention to the nose

cutout hole (if planning to use the wood button detail).

Immediately . . .

. . . press glued up assembly under a heavy flat object

such as the thick book shown here, with something

else heavy on top. Allow to dry for several hours or

overnight. Pressing layers flat that have been glued up

with liquid adhesive is essential to minimize warping

or curling. (NOTE that Steps 3-4 can also be completed

prior to the pressing step.)

3. Position and attach the head base top panel as

for other head shapes as shown in Step 2, then

position and attach eyes contrast in the eye cutout

window. Press again.

4. Position and attach face shape onto lower portion

of head assembly, enclosing eye contrast panel

between. Align cut edges that match up precisely.

Press under heavy weight.

5. Position and attach fur strip and tassel ball on top

of the hat shape where edges match. Press flat.

6. Position hat assembly onto head base above face,

pushing cut edges at mid line together snugly.

Press flat.

7. Prepare each set of boxing strips by bending

edge tabs and flanges  back and also vertical perforation

lines between side, corner and top/bottom

segments.

8. Become familiar with the ID markings on box panels.

Here, the LID main panel includes 'L' cut near top,

and the BASE main panel includes two "bite" marks

along top panel.

Also NOTE that LID main panel and interior panel

appear to be nearly identical sizes, and can be

distinguished from BASE by nose button holes.

Identify the main shape by the 'L' cut.

In a similar way, the BASE main shape includes

the "bite" marks, so by default, the final panel

is the BASE interior panel.

The base strips also include identifying markings:

BASE strips have "bite" marks on end tabs,

and LID strips are plain.

9. Position, align and glue appropriate boxing strips

together, first end, then . . .

. . . form the assembly into a ring to align and join

the second end.

10. Repeat for second set of boxing strips.

11. For LID, bend top tabs and flanges inward

at perpendicular angle, apply glue, then position

LID main panel over opening, adjust to align each

edge of panel with tab or flange perforation edges

and attach in place.

Invert the assembly then apply pressure (without

un-adjusting alignment) around tabs at panel edges.

12. Apply glue to LID interior panel underside,

then insert into the LID main assembly.

(This will be a snug fit.)

Press all edges with fingertips to ensure alignment.

If possible, use appropriately-sized weights to

press the panel flat until dried.

13. Repeat Step 12 for BASE to complete "tray"

in same manner with main and interior panels.

14. Apply adhesive (preferably quick-grab such as

Fabri-Tac) to main lid panel, then position head

assembly, centered, over lid panel.

Take care to align the nose hole cutouts of

head with lid panel as well as . . .

. . . checking on backside of head panel to align

center bottom of beard to center bottom of tray.

15. When head is securely attached to LID,

apply glue to painted wood button nose, then

insert into the hole and hold until secure.

(Or position and attach alternative nose circle cutout

or cutout stack over hole.)

16. To finish box gift, use a sticky dot or equivalent

to bottom of BASE tray, insert and position and attach

gift card in place.

Fit LID over base with base walls inside LID walls.

NOTE this should be a snug fit so that the two

box parts will not fall apart when closed.

Here is the completed Santa Gift Card Box, with . . .

. . . a side view showing box.