Needles 'n' Knowledge: Tote 3D Container Panel Prints

Sturdy decorative container has upper rim that gives

appearance of thick walls, with tall decorative uprights

composed of built-up layers supporting a hexagon

tube-wrapped 3/4" diam. dowel handle.

Interior cross-wall partition creates two compartments.

Add offset panels as decoration, then tie

decorative tag to the handle.

Sized to coordinate with specialty printed panels

(shown here with Graphic45's
“Place In Time February Cut-Aparts”),

including extra shapes to trace and prepare

“chipboard” built-up base shape embellishments.

Measures approx. 7.75” tall x 8” long x 4.25” wide.

ASSEMBLY: 1. Identify and cut the shapes:
A box front with attached bottom panel
B box back C box sides (2)
D handle tube E partition panel (*8 layers)
F front, back accent panel overlays (2)
G side accent panel overlays (2)
H box bottom reinforcement panel (1 or more)
I upright panels with "inward" build up layers (2 sets of 7* ea.)
J upright panels outward "face" shapes (2)
K upright offset accent overlays (2)
*see steps 2 & 3 for information to determine
exact quantity of layers required

2. Each upright will consist of multiple layers of card stock

of the hex post hole shape plus single non-hex hole

shape outward "face" shape

that are built up to match the width of the slot

on main hull front and back where they will

eventually be inserted.

To determine build up layers quantity to cut,

cut approx. 8 of the upright shapes

(simulated here to include the 7 hex hole shapes

plus single non-hole face shape),

and layer (but don't glue yet), and stack.

Test this quantity to see if the stack will fit comfortably

through the slot cut out of the front/back panels.

If too loose, add an additional layer, test, then

finalize the quantity needed, and cut out.

If too tight, remove a layer, test, etc.

3. Complete a similar thickness test for the partition
shape, by layering 8 rectangles, then . . .

. . . test for fit by inserting the stack into the slot

of the upright shape. Add or subtract layers as needed

to determine the final count.

4. This tote project was specifically designed

to use the various panel shapes of the Graphic45

printed panel card stock mentioned in the introduction.

Shown here are the add-on panels and embellishments

used in the final project, together with their stacked

duplicate shapes or accent panel underlays, etc.,

provided just for information and inspiration.

5. Layer and attach the upright layers into a stack

as determined in step 2,

but NOT including the non-hole face shape

(which is added later in the assembly process).

Take extra care to make sure that all cut edges

are aligned as precisely as possible,

particularly at the hex hole opening and slot edges.

Immediately press the glued-up stack under a flat weight

or heavy object such as the fabric-covered,

re-purposed weight machine bar shown here

(the upright requires two bars placed side by side)

until the glue is completely dried.

Pressing with weights will help minimize warping

or curling of the glued-up shape when using liquid glue.

This may require several hours.

Also NOTE that the 8 or so layers required for

the upright thickness may need to be stacked

in a couple of sessions, allowing the first 5-6 stacked

shapes to dry, before attaching remainder.

6. Layer the partition wall in similar manner,

taking care that all edges are aligned

as precisely as possible, stacking and joining

part, allowing stack to dry, then attaching remainder.

Use a flat weight to press the partition shape

until it is fully dried, for several hours.

7. Prepare the back panel by bending on the perforation

lines as shown, all back (mountain folds) except

for the inner flange tabs shown here at top.

8. Identify the dashed line guide marks approximately
halfway down the panel. These will be used toward
the end of the assembly as a way to guide
the final positioning of the flange tab edge as walls
are completed.

9. Prepare the front/bottom panel in similar manner,
noting that the perforation line indicated is
the connection of the front to the bottom panel.

10. Prepare the side panels in similar manner,

bending back at side flanges and interior (rim)

perforation lines, and forward at inward flange perf line.

11. Assemble the box base by aligning and joining

the front/bottom with the back panel at bottom flange,

then adding the side panels to connect with

the bottom panel at center.

12. For strength and a little extra weight,

position bottom separate reinforcement panel

onto the bottom of the box assembly, within

the perforation lines or panel edges that

define the box bottom. (Add additional layers

as desired and cut.) Press with flat weights

until the panel(s) adhesive is completely dry.

13. Position and attach the accent panels

to the outer surfaces of front, back and side walls.

14. Bend the walls back to overlap straight edge

of front/back panel over adjacent flange, adjust,

and complete side seam.

Repeat for 3 remaining corners.

14. Prepare the handle post wrap shape by

bending back on the long perforation lines,

and at the end tab lines.

15. Form the shape into a tube to overlap
the straight edge over the opposite flange to
perforation lines and glue in place.

NOTE that the side seam can be completed by
flattening out the tube shape, or by wrapping
it around the 3/4" dowel and forcing the edge
inward to overlap the flange to perf line.

16. Prepare to measure the dowel piece needed

as handle insert, by bending tabs forward,

sliding dowel cut end to be even at top, then . . .

. . . mark the dowel length even with the shaft

of tube wrap, with bottom tabs bent out of the way.

Cut the dowel as marked, with exact perpendicular cut.

17. Insert end tabs of first post end through hex hole

front inside toward outside . . .

. . . until tabs are fully through to backside, then . . .

. . . bend tabs outward and glue in place.

18. Position "face" upright shape over the assembly

to enclose the post tabs, and glue in place.

Use flat weights to press this attachment until dry.

19. Repeat the process to insert the second end

of post tabs through second upright stack,

bend and glue tabs to backside, position and

attach second "face" shape over the assembly

and glue in place, using flat weights to assist

drying process.

19. Bend front and back box walls toward center,

then complete a "test run" or insertion by

carefully inserting bottoms of upright/handle assembly

into the rim slots, and . . .

. . . slide down fully into position where the upright

straight bottom edges seat at box bottom.

Lightly mark the wall height onto the face of

each upright. This mark will indicate the level

below which adhesive can be applied.

20. Remove uprights, apply glue tape or other adhesive,

then re-insert and attach outer wall backsides to

respective front or back upright.

21. Apply adhesive to the bottom and ends of

the built-up partition wall.

Position the partition inside the middle of box,

and insert first end into the upright slot, with bottom

flush against box inside bottom surface. Then . . .

. . . swing the second partition end into the corresponding
upright slot. Apply pressure to attach the partition in place.

22. Bend the front and back interior walls down

into final position, with the flange edges aligned

at the guide mark perforation line

(NOTE there is a step-down transition between

the thickness of the uprights and main wall;

attach the flange to each as neatly as possible.)

When the walls are in correct position, the rim

portion should be at a ninety-degree angle

to the outer wall.

23. Prepare the bend the side wall inward by

first applying a dab of glue at "inward triangle"

portion of end of front and back wall rims, and . . .

. . . apply glue to the underside of the end flange.
Then bend the side walls inward as with
the front and back walls, positioning flange edge
at perf guide lines, with side wall rims overlapping
the ends of adjacent rims to form a miter "seam".
Apply pressure to join where glue was applied.
Repeat for second wall attachment.