Tuesday, April 7, 2020

Bunny Run 3D Block Box

Shaped lid fits snugly over "reversed" base, 
which are glued together to form the imitation 
“wood block” onto which the front layered decorations 
of running bunny are attached. Cut shapes include 
a stylized layered bow and streamers. 
Or, to replicate the sample project, use the alternative 
box lid front panel and body shapes that allow a satin ribbon 
to be threaded through a pair of slots, 
simulating having tied ribbon around the bunny. 
Measures approx. 6.125” long x 4” tall x 1.25” deep. 

ASSEMBLY: 1. Identify and cut the shapes:
A bunny box LID front panel (ribbon slot option)
LID boxing strips: B bottom; C back; D top/front
E BASE back panel
BASE boxing strips: F bottom; G back; H top/front
I BASE support/reinforcement strut strips
bunny decoration: 
J base panel shows thru as back left leg (slot option);
K body front with contrast tummy and tail;
L head base shows thru as left ear;
M head front with eye and nose
2. Assemble the bunny decoration, then place under
a flat weight to press while box is assembled.
Here the subtle differences between the base and
front body and head shapes is more easily seen
for the model project, helping to create a dimensional
appearance and the suggestion of shading.
(Base body, head are darker than overlaid shapes.)
Position the body front over the body base and align
all cut edges that should match up. If the slot option
has been selected, take particular care that slots
of the two layers line up. Also layer head front over
head base in the same manner.
Layer the head assembly over the body base assembly,
lining up the cut edges as precisely as possible.
Attach the eye into the cutout, nose onto the front tip.
Position and attach the tail and tummy where they fit.
3. Prepare to assemble the LID by adding a little curl
to the segments of the bottom boxing corresponding
to the series of tiny tabs (these will fit around the curved
edges at front leg, tummy, back feet). NOTE that
this is easier to accomplish before the tabs are bent.
Here it is easier to see the multi-tab segments
where the curl should be added that will assist
with the edge shaping to match body edge.
Each length of boxing will include tiny cutout symbols
such as the circle shown here that is at the lead end
tab for the LID bottom boxing. A corresponding symbol
(in this case the circle) will be found in the top tab
of the top/front strip where the end will join to this tab.
Symbols assist to understand which strips join where.
LID has single circle, square or triangle symbols.
BASE has double symbols in equivalent positions.
These illustrations show where the ends of strips will be
located along the LID or BASE to assist with assembly.

4. Bend the edge tabs back, and also bend on each of
the segment perforations (these bends may need to
be re-directed as it becomes more clear how they fit).
To more easily understand where the boxing strips
will be attached, it may be helpful to lay them out 
around the panel, as is shown here.
5. Begin at the front angle between the head edge
and the front leg on body panel, and align the first
segment edge of the bottom strip . . .
. . . overlap the body straight edge to the strip's
corresponding segment tab perforation line, and join.
6. For the next segment - leg's curved plus straight edge -
shape the strip segment to match, and line up 
the next perf line bend at the leg and tummy angle .
NOTE that this edge includes approx. 1/2" that is straight
(without multiple tabs). Press the edge end of the segment
into position and hold until attached, then . . . 
. . . push in and make any adjustments necessary to
accurately fit the strip to the body shaped edge.
Once the strip's tabs have grabbed enough to not shift,
it will be helpful to turn the assembly face down on flat
work surface and apply pressure along the tabs to secure them.
7. For the next segment - tummy curved edge - 
repeat the process of lining up the end bend at
the tummy/leg angle, adjusting and attaching.
8. Continue working along the lower edge to position,
attach end of curved segment to corresponding
angle (for forward leg, later for back leg) or for
straight edges, until all segments of bottom strip
are attached in place.
9. Position the "square" symbol end of the next strip
so that end tab flange can be inserted under the first
strip's end edge, then glue in place.
10. Position and attach each strip segment (remaining
are all straight edges) to position, adjust and attach
all edges of this back/top strip.
11. Position the "triangle" symbol end of the final strip
so that end tab flange can be inserted under the first
strip's end edge, then glue in place.
12. Position, adjust and attach tabs at head front edges
until only a couple of edges remain unattached, then . . . 
. . . pause to apply glue to the lead end flange
as well as final tabs before . . .

. . . final edges and tab
is attached to complete the LID boxing assembly.
13. For the BASE, repeat the boxing attachment steps
(in mirror image to LID so that they can eventually
fit together) using the twin symbol strips, positioned
as is shown in the illustration at end of Step 3 . . .
. . . beginning with the twin circles at the front leg bend.
14. Strut strips will be inserted and attached at
specific locations to help stabilize the BASE, and
prevent the box from compressing.
Each strip is a different length, identified by the A, B or C
cut in each. Bend back the end tabs.
This illustration shows where the struts will be placed
to bridge the interior space and attach at boxing bends.

Here the struts have been "dry fit".
15. Bend or re-direct the end tabs for easiest attachment
at the boxing angles, then position and attach in place.
16. Position the bunny body assembly over the face side
of the LID, and attach in place.
For the ribbon slots option, take particular care
that the body slots and LID slots line up.
17. Thread the lead end of a 15-16" length of ribbon
(5/8" wide is used here) through the first slot,
then pull halfway through to backside, then thread
back up through second slot.
Adjust to center the length, then tie knot and bow,
trim ends as desired.
18. Fit the BASE into the LID . . .
. . . and push down into place fully.
Use quick grab glue applied between the walls along
strategic areas (nearly but not completely all around)
to join the two components together.
Here is the completed bunny block box with ribbon.

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