Thursday, September 7, 2023

Bat on Wire

Easy-assembly dimensional bat is composed of 
angular thin “box” sandwiched between front & back wings, 
with layered-for-thickness front and back bodies. 
Insert a sturdy gauge wire length into 
body “box” bottom pierced hole, shape, then thread 
through anchor hole and into tiny box stand 
(weighted with hardware metal washers stack inside). 
Bat can be used as floral pick or cake toppers, and more. 
Coordinates well with "Halloween Countdown Blocks Stand"
(separate design; find that assembly guide HERE).
Bat measures approx. 3.5” wide x 1.75” tall x .375” deep; 
stand measures approx. 1.125” x 1.125” x 1.125”. 

ASSEMBLY: 1. Identify and cut the shapes:
A & C front and back wings with body
B & D body stacks (5-6 each) for front and back
E body boxing   F body interior panel
G stand box to hold wire   H box interior support
2. Layer and attach together the body shapes for
front body stack, then for back body stack, taking care
to align all cut edges as precisely as possible.
Place glued-up stacks under a heavy flat weight
such as this muslin-wrapped repurposed free weight bar
or a book or heavy wood plank for several hours or
overnight to prevent warping or curling due to gluing
with wet adhesive.
3. Position each body stack on front of wings with body
shape, taking care to align corresponding edges
at head/ears and bottom body curve as precisely as
possible. Press under a heavy flat weight as
described previously.
4. Prepare the body boxing strip by bending back on
all perforation lines for segments, edge tabs and end tab.
5. Form the strip into an irregular ring to overlay straight
end edge across opposite tab (tab will be inside ring)
and glue seam.
6. Bend bottom edge tabs inward to create a shape
that is roughly like a square-topped coffin
(NOTE this image shows boxing ring top down)/
Add glue to backsides of all tabs, then slip inner
body shape into boxing and adjust so that body
boxing conforms around body shape.
Apply pressure to attach tabs to body edges.
7. Position boxing over wings/body backside assembly,
taking care to center side to side as well as up and down.
NOTE: the rounded end should be positioned at
bottom to echo the rounded bottom edge of bat body.
Apply pressure to attach body boxing assembly.
8. Cut a length of sturdy gauge wire at approx. 8-9",
then use a thick rod form such as this 1" diam.
wood dowel to form a loop in the center of length.
9. At bottom panel of "rounded" boxing bottom,
locate the tiny poke hole, and insert wire end
up into body.
At the end, add a curl with needle-nose pliers, then . . .
. . . use hot melt glue to attach curl to body backside
at approx. mid height. Allow to congeal and
attach in place.
10. Position the second wings/body assembly over
the boxing with wings assembly, making sure that
body boxing is centered in same way that body was
first positioned on first wings/body assembly,
and attach in place.
Apply pressure to join all the elements.
11. Prepare the base box stand by bending back
on perforations for panels, edge and end flange tabs.
12. Form the center portion into a ring to align
and join straight edge and tab seam.
At bottom (end without hole cut out), bend side tabs
inward, bottom "cap" up to join in place, taking care
to adjust box cap in squared up position.
13. Prepare a weights stack by gluing 6-7 1" washers
into a stack with hot melt glue, taking care to align
outer edges precisely.
Insert the washers stack into box stand, center and
glue to box bottom.
Fill the hole with hot melt glue and allow to congeal.
14. Bend the interior support shape's edge flanges
up and apply adhesive to underside of flanges.
Insert into box stand interior, square up to attach
edge flanges to interior surfaces of walls.
15. At top, bend the tabs inward, cap panel down
to join to complete the cube box. Allow to dry.
16. Prepare to insert bat wire into box stand top hole
by first heating the end by touching a hot iron or
over a match or candle flame. Then immediately
insert wire end through box top hole, fish around
to insert wire end through interior hole then down
into hot melt glue at center of washers.
Hold in place until wire feels secure. 
Here are a pair of bats with anchored stand boxes.
If combining the bats with the Halloween Countdown
Blocks Stand project, refer to Steps 6-12 in
the tutorial for that project HERE.


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