Christmas Word Ltr Boxes Part 1 CHRIS
(This is a placeholder post for
a soon-to-be-completed project:
a soon-to-be-completed project:
CHRISTMAS LETTER BOX ENSEMBLE.
This post will provide assembly guidance for
Letter Boxes C-H-R-I-S [small].
A separate post will present assembly of
remaining letters T-M-A-S [large].
When the two "halves" of the letter boxes
are combined, with some letter boxes being
replaced by dimensional elements,
a masterful and long ensemble can be
completed. That project will be described
and some assembly guidance offered
in a third, separate post, HERE.)
ASSEMBLY: 1. Identify and cut the shapes:
for Letter C -
A LID front panel
B accent front panel overlay
C LID boxing strips
D "sprigs & twigs" spine and branch overlays
E left & right arc sprig overlays
F cedar berry assemblies (2)
G BASE back panel
H BASE boxing strips
A LID front panel (hex post opening version)
B front panel accent overlay
C LID boxing strips
D opt. hexagon post shape
E BASE back panel
F BASE boxing strips
for Letter R -
A LID front panel
B accent front panel overlay
C LID boxing strips for outer walls
D LID boxing strip for interior opening
E BASE back panel
F BASE boxing strips for outer walls
for Letter I -
A LID front and side walls "tray"
B BASE back and side walls "tray"
C Front accent panel overlay
for Letter Small S -
A LID front panel
B accent front panel overlay
C LID boxing strips for outer walls
D BASE back panel
E BASE boxing strips for outer walls
NOTE: thorough description and illustration of
Letter Box C are shown here. This letter shape
and assembly provide good general steps for
other letters because C includes both straight edges
and curved edges.
LETTER BOX C
2. Become familiar with symbols and markings onthe boxing strips. When strips need to be connected
around letter panel shape, there are symbols such as
a tiny triangle, tiny circle, asterisk or 'X' in the end tabs
and in edge tab(s) near the straight end edge . . .
. . . where the joint will be made.
The BASE set of strips will include double symbols.
Also, each set of boxing strips for a LID will include
a line cut letter identification. Here is the tiny 'C'.
a tiny #1 symbol.
3. Sections of the boxing strip that will attach around
the curve have a series of many small tabs. The strip
should be shaped before bending the tiny tabs back.
Use a narrow rod tool such as this dowel placed
behind (for back curl shaping) or in front of (for
front curl shaping), then apply pressure with thumb
while drawing the strip across the rod, sort of like
curling ribbon is drawn across a scissors blade.
Add enough curl to match the curving edge of
letter panel.
NOTE that it will be helpful to place the front letter panel
on work table then arrange wall sections around letter,
using #1 symbol, connection symbols, etc., to help
visualize how they will fit. If necessary, re-bend segment
edge tabs or end tabs into the required positions.
(An image showing this step for 'C' is not available.
To view the 'H' letter box with this layout, skip forward
to Step 25, then return here.)
4. Bend perforation lines back, and tabs back.
5. Position the #1 tab at the downward edge of
upper curved arm, overlap letter straight edge across
tab to perforation, adjust for top and bottom segment
to edge alignment, and join tab seam.
6. Bend boxing around to the top of the 'C', locate
the subtle corner that defines the end of the curve
and the beginning of the top straight edges.
Apply adhesive to the curve tabs and the top straight
tab, then . . .
. . .position the next segment perforation line
exactly at the corner . . .
. . . and align the straight tab along the straight edge.
(The end of "straight" should come exactly at
the next corner angle that transitions to
the next curve.) Join the straight seam, then . . .
. . . once that portion of the seam is secure,
immediately return to the skipped curve segment
and ease the tab bends inward to align
as precisely as possible along the curve of letter.
NOTE that once the curve tabs are sufficiently
attached, it will be helpful to invert the work onto
work surface and apply fingertip pressure all along
the curve until very secure.
7. Repeat the process for the next curve section,
locating the cut mark that defines the end of curve . . .
. . . positioning the straight to begin attaching
at that guide mark, align and attach. Then . . .
. . . ease the curve tabs in to match curved edge.
8. The next strip will need to be added at this point.
Identify the next strip with coordinated symbol,
add curl to curved segments, then . . .
. . . overlap the straight end edge across the
end tab to perf, adjust for top to bottom alignment,
and glue the seam.
(NOTE: for final cut file, the tab was moved
to be on second strip.)
9. Continue the straight-first alignment and attachment
followed by curve ease-in process to attach
along bottom to front edges.
10. The next/final strip that will be attached includes
the tighter inward curves. Use the rod tool to add
narrow radius curl at tabbed segments, even
rolling the card stock right around rod to get
the curl that simulates the 'C' edge where it will
be attached.
11. Attach the strip to end of previous strip end.
12. Position and attach the lower arm top segment.
13. Assist strip to "turn the corner", then repeat the
process to add glue, position and attach the center
straight and ease in the lower curve.
At top, prepare the final curve of boxing to fit
the 'C', and at the same time, tuck the end tab,
behind the lead strip end, and join that straight seam.
Return to ease in curve and attach, apply
backside fingertip pressure, etc.
The 'C' LID of the box is now complete.
15. NOTE that the BASE 'C' panel includes a pair of
"bite" marks to help identify it as the BASE panel.
Because it is the mirror image, the process will be
the same, but clockwise instead of counter-clockwise.
Locate the #1 symbol end panel, then . . .
. . . position and attach to the upper arm straight
edge. Follow the same steps used for the LID
to complete the BASE.
16. Complete the box by fitting the BASE inside
the LID walls as shown, then . . .
. . . push in until the BASE is fully seated.
Once there is no reason to open the box again
(such as having access to thread twine to
attach jingle bell element), secure the box closed
by applying glue between the layers near opening
edge, then press all around to shape inner and
outer curves and straights to attach as
tightly as possible.
17. To add the embellishments, position and attach
the 'C' accent overlay with narrow offset margin
all around.
18. Locate the small guide mark punch on
overlay, and also on the "spine" branch,
then align and glue spine in place, more or
less centered up center of overlay.
It may be helpful to press the glue-up with a moderately
weighted flat object such as a book until dry.
(Repeat this step throughout the process as needed.)
19. Assemble the cedar berry cones by layering
the bottom shapes centered with end edges matched,
then add the third and top shapes. Press until dry.
20. Here are diagrams that show remaining twigs
and sprigs placement. Also refer to notations within
the cut file.
NOTE that each of the twigs will be positioned
so that base end will be placed at a knob on the spine.
Begin at the bottom to add the F twig, then continue
upward to work in reverse letter order . . .
. . . to position and add E, etc.
21. The sprig shapes can be positioned more
"artistically" (no guide marks). But pay attention
to the slight curve, if you wish to duplicate the sample.
22. Finally, position and attach the cones.
Decorated 'C' box is now complete.
LETTER BOX H
NOTE: For similar straight edge boxes, including 'T',
the process for 'H' will be similar. Read through steps
and apply assembly principles where they match up.
23. If completing the decorator project with cardinal
and post, prepare the post shape by bending back
on all perforation lines, except bend forward
at end tabs.
24. Bend the side edges to overlay straight edge
to overlap adjacent wall straight edge to perf line,
and join seam.
NOTE: that scale of this little "box" may require using
the end tip of a tool to present a press against
surface to apply seam pressure.
Complete the remaining 5 seams.
When the H LID is complete, if you are using the post
version, the hex form will be fit from behind through
the hex opening in face panel (with accent in place).
25. Bend boxing strips back on all perforations,
then re-bend forward at "bridge" corners.
To help visualize how the boxing strips will fit
around the H front panel, so that the panel
perforation bends can be directed correctly,
bend and arrange the boxing strips as shown.
26. Position #1 edge of boxing along lead edge of
'H' as shown, adjust for top and bottom alignment,
then overlap boxing flange tab to perf line, and
glue in place.
27. Continue working around the 'H' shape to position,
adjust and glue segments to edges: top leg, then . . .
. . . inner arm, then . . .
. . . top face of bridge . . .
Join next strip on as described above for letter 'C',
then continue . . .
. . . to position and attach remaining wall segments,
joining . . .
. . . third segment when needed . . .
. . . until final strip is being fit around lower bridge
and leg.
As final segments are being positioned, it will be
more convenient to apply adhesive to remaining
flanges or edge tabs, including the end tab
(which may be attached to edge #1 as it is for 'H'),
and swing them into position in one operation.
28. Position and attach the accent overlay, taking care
in this case to align post hex opening edges
as precisely as possible.
29. As described previously, insert the hex cap
through the cut out from backside of LID . . .
. . . and push through completely, then . . .
. . . attach tabs to backside.
30. To close, fit BASE into LID backside, glue layers together.
LETTER BOX R
NOTE that more complete assembly guide steps
can be followed HERE in steps 54-62.
31. Prepare the boxing shapes for straight and curved
edges in the usual way as described in 'C'
assembly. The opening has its own boxing shape
which has inside tight curves plus straights is
prepared similarly, with joining tab being attached
behind the adjacent edge so that it will be
invisibly on the inside of LID.
32. Position and join edge #1 as described for
other letters, then proceed with straights and
curved in similar process until all of outside
walls are joined.
33. Apply adhesive to the joined opening boxing,
then fit it over and around opening edges.
Invert to check edges from front side
and make adjustments as needed, then apply
fingertip pressure along seams.
34. Complete BASE, then fit together and finish.
LETTER BOX I
35. This letter with its simple shape is assembled as
a simple box BASE with LID.
Prepare by bending back on all perforation lines
for panels and tabs.
36. Bend side and end walls together and join corner seams.
37. Attach accent overlay, then fit the two parts
together and glue together.
LETTER S BOX - SMALL
38. Refer to the large 'S' box in Part 2
beginning at Step 11 to assemble
the slightly smaller box.
39. Remaining letter boxes are found in Part 2
for the Christmas Letter Box Ensemble.
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