Leprechaun Torso Gift Card Box

 This dapper and magical fellow – at least the top half of him – 

is presented in sturdy layers on top of 

a low-relief gift card box. 

Many layered details make him especially festive. 

Box measures approx. 2.37” side x 3.68” tall x 

.75” deep to hold a standard gift card. 

Leprechaun figure measures approx. 3.6” wide x 5.4” tall 

when fully assembled. 

ASSEMBLY: 1. Identify and cut the shapes:

A figure silhouette (4-5 for build up thickness)

B front silhouette (shows thru as hands with inlay cut outs)

C eyes, mouth contrast inlays

D face overlay with eye and mouth cut outs

E shirt   F cuffs & buttons

G beard overlay   H mustache, nose, eyebrows

I vest, button   J collar   K bowtie base, overlay, knot

L hat base, band, brim & shamrock

M LID box outer panel (L)    N LID box inner panel (LL)

O LID boxing strips (2)

P BASE box outer panel (single notch)

Q BASE box inner panel (double notch)

R BASE boxing strips (2)

2. Layer and glue together the figure silhouettes for thickness,

taking care to align all cut edges as precisely as possible.

3. Working quickly, position the front panel on top

of the silhouette stack, align all outer cut edges

as precisely as possible and attach in place.

Position and attach eyes and mouth into

corresponding cut outs.

Immediately place the assembly on a flat surface

and press under a heavy flat weight such as this thick

book, with something else heavy on top, and leave

in place until thoroughly dried - requires several hours

or overnight. Pressing will help minimize curling or

warping of the liquid glued-up shape.

4. Assemble the hat component by . . .

. . . layering and attaching the band in place, then . . .

. . . overlaying the brim at lower edge, then

position and attach the shamrock accent.

5. Position (center) and attach the vest on top of the shirt

with upper corresponding edges aligned, then . . .

. . . position and attach the button in the cut out window.

6. Prepare the bowtie by layering the front shape

with "fold" cut outs on top of the contrast base

shape (shown upside down here - ooops)

and knot on top.

7. Assemble the face unit.

Position and attach the beard where it fits along 

the bottom of the face shape, and the mustache

centered above the mouth cut out.

Then position the nose abutted next to the mustache

at the top shape where it fits, eyebrows over

the eye cut outs as shown.

8. Finalize the torso assembly: A) position

the shirt/vest unit over the bottom portion of

the silhouette shape where it fits and attach in place;

B) position the collar shape over the vest, centered

and with the top edges aligned with shirt/silhouette

edges and attach in place;

C) position the face/beard shape over the assembly

matching the side "ears" and beard edges of

all layers, then attach in place;

D) position hat at top of assembly where edges

match, and attach in place; E) position and attach

bowtie below the beard bottom tip.

BOX ASSEMBLY

9. Click on this LINK and follow the "Box Assembly"

Steps 1-4, then return to this post for a slightly

different assembly of box LID and BASE.

10. Identify the inner BASE "floor" shape by finding

the double notch cut out along one end edge.

Prepare the BASE boxing shape as shown.

11. Bend the boxing strips tabs inward at right angle,

then apply liquid on the inward surface.

Insert panel inside the boxing frame and . . .

. . . push fully down into position, allowing the boxing

to shape itself around the panel. Apply pressure all

around edges to attach to boxing tabs.

Be sure to make sure that the long or short side walls

do not bow outward at all, but stay tight and

parallel to the panel cut edges.

12. Reverse the BASE box.

Apply glue around the boxing edge, with

some in the center as well.

Position outer panel over the bottom and center

it so that all outer edges are even.

If possible, consider placing the BASE shape on a flat

surface with something heavy to press down the panels

to assist them to attach fully to boxing tabs, such as

this wood cut off, or several same-height thread spools

placed along edges and inside boxing, with something

else heavy pressing them down. Leave pressing tools

in place until seams are fully dried.

13. Repeat the assembly process for the LID,

using the interior panel with 'LL" and the

exterior panel with 'L'.

14. Apply adhesive (quick-grab suggested, such as

Fabri-Tack) to the outer panel of the LID, then

position it behind the torso assembly . . .

. . . where side edges and bottom edges of LID

will be concealed by torso edges.

If the bottom end of the LID box is placed

near the bottom of torso, it will assist the box

to stand when filled and fully assembled so

that it can be used as a decoration as well.

15. To close the gift card box, place the card

inside (possibly held in place against BASE floor

with a temp hold sticky dot, etc.), then fit the LID

over the top of BASE. That is, BASE walls should

fit inside of LID walls.

Push LID fully down into place.