Wednesday, July 1, 2020

Tall 3D House Colonial with Leanto

Square hull in the “saltbox” style has accent panels, 
see-thru upper windows with detailed frame and sash 
built-up overlays, dimensional front step with layered door 
and built-up frame, interior platforms for strength and stability, 
opt. LED tea light cup to illuminate vellum window panels, 
back trap door for votive access. 
For a patriotic display, prepare and attach 
the “Flag Colonial Stylized” decoration for hull size, 
using optional accent with punch holes to pierce for 
brads to position and “hang” flag if desired. 
Measures approx. 4.5” deep x 4.5” deep x 10” tall 
plus 1.8” deep leanto add on. 

ASSEMBLY: 1. Identify and cut the shapes: 
A main hull front and side
B front accent panel overlay  
C tall side accent panel overlay
D roof crestline support triangular 'box'
E shaped roof (flat) base with edge flanges and slots
F shaped roof with cut-in connection tab rows
G roof section overlay strips (8)
(not shown: roof angle side fascia overlays)
H front step 'box' with connection tabs
I door wreath: 3 unique shapes to overlay
J front windows array (see larger layout following)
K door base, overlays, top & bottom slats and door frame
(not shown: frame top 'lintel' strips)
main hull back and side
M back accent overlay with trap door cutout
and separate door overlay
N leanto side accent overlay with slots
O interior lower reinforcement 'tray'
P interior middle reinforcement 'tray' (holds tea light cup)
Q trap door closure 'stop' circles
R tea light cup
S star accent base and overlays for build up (3-4)
U leanto hull
V, W & X leanto overlay accent panels
Y leanto base interior accent 'tray'
Z leanto roof panel with side flanges and end tabs
AA leanto roof overlay 'shake' strip (top)
BB leanto roof overlay 'shake' strips (4)
C leanto window assembly
Window assemblies details:
Extra shapes for overlays are cut to layer for 
 door and windows build up to add dimension.
Each window for main hull and leanto consists of
panes grid base (shown as dark here; changed to match
frame before project was finalized), 
frame (2), top sash strip (2) and bottom sash strip (2).
Vellum 'glass' panels are also cut to add behind panels
grid base (for more opaqueness, project uses 2 vellum each)
Door consists of contrast base (to show through slat slots)
slat overlays (2), top & bottom slats (2 each), knob circles (2-4).
Door frame consists of inverted 'U' frame (2) and
upper 'lintel' strips (2).
2. Prepare components that need to be layered
and glued up, pressed and allowed to dry:
A) window frames - layer frame shapes with edges
matched exactly; layer upper and lower sashing;
add sashing strips to top and bottom of frame;
add pane grid behind frame (project's final pane grid
matches the frame, not contrast as shown here).
To assist the glued-up assembly to remain flat,
to avoid warping or curling that comes with using
liquid adhesive, use a flat heavy object to press flat
during the drying process (hours if possible), such as
the fabric-covered re-purposed weight bar shown here,
or a heavy book, etc.
B) Position and attach vellum panels behind the grid frame.
For this project, a doubled layer of vellum was used
in each window (as shown above), resulting in 
very dull tea light show-thru.
After review, a single pane would be more desirable. 
C) Position and attach the star accents for build up
(thickening of star), then . . . 
. . . position and attach the star to the 'hanger' base.
Press flat while drying.
D) Layer the three wreath shapes with punch hang hole
aligned at top, and adjust layers for best symmetry and
'show through', then glue hang hole ring together,
and a couple of overlapping spots near bottom.
Press flat while drying.
(No images for door assembly)
E) Layer and glue together door panel shapes; 
layer upper and lower slats; position and attach slats
to panel assembly; position and attach front assembly
over contrast base; add door knobs as a stack into cut hole.
3. Prepare the front step 'box' by bending back on all
perforations for panels, ends, cut-in tabs.
4. Begin to form the shape into a long narrow box by
bending the end panel tabs inward, then bend ends
back, then . . . 
. . . form the long walls into a tube, with
the cut-in tabs allowed to extend outward, long flange 
side panel to tuck under, and glue all seams.
5. Prepare the house hull front shape by bending back
on all perforations for panels, side flange tabs, roof.
Position and attach the front and side accent panels,
taking take to align bottom straight edges flush,
and check that cut-out opening edges align as
precisely as possible. If using liquid adhesive
be sure to press flat under a large flat weight
until dried completely (make take several hours).
Otherwise double-stick adhesive such as the tape-runners
is highly recommended for these straight-edge shapes.
6. Position and attach the window assemblies
centered over the window cutouts.
Press flat while drying is using liquid glue.
7. Prepare to position and attach the door frame
onto the front panel by identifying the alignment cut marks
on the accent panel, then . . .
. . . position the frame between the sets of marks
to center the frame, and also position the bottom edges
to be exactly above the door stop slots.
To double check the height positioning, "dry fit"
the front step in position at lower front edge of panels,
then snug the frame down to touch step upper surface.
Glue in place; press under flat weight until dry.
8. Position the door assembly into the door frame
(this should be a snug fit), and glue in place.
Glue in place; press under flat weight until dry.
9. Prepare the house hull back shape by bending back
on all perforations for panels, side flange tabs, roof.
Position and attach the back and side accent panels,
taking take to align bottom straight edges flush,
and check that cut-out opening edges align as
precisely as possible, like the front hull panel. 
Also position and attach trap door overlay 
aligned at the right finger hole edges so that 
the door can be opened and flexed fully.
NOTE that the 'window' opening in the tall side 
is intended to allow tea light candle light
to "spill" into the leanto that is attached at the slots
so that the window is slightly illuminated.
The back trap door allows for the tea light to be
inserted, removed to turn on an off, etc.
Also make sure that the leanto attachment tab slots
are fully aligned so that tabs can be inserted.
Using a tool such as the spatula shown will assist this.
10. Position and align the house hull halves so that
the straight edge of one overlaps the long side flange tab
of the other, to the perforation line, and join the seam.
11. Form the hull into a tube to bring the opposite
edges together in the same manner to complete
the second side seam. NOTE that because they are
symmetrical, the assembly can be laid flat with fingertip
pressure applied along the seam to ensure it is 
fully joined.
12. Prepare the lean to hull shape by bending back
on all panel edges, roof angle flange tabs.
Position and attach accent overlay panels as was done
for main house hulls.
13. Position and attach the leanto window assembly
over the window opening as was done for front panel.
14. Bend the side flange down, and roof edge into
position to align and join the seam. Repeat for 
the second seam on opposite roof edge.
15. Prepare the leanto base reinforcement 'tray' shape
by bending forward all flanges.

16. Position the tray into the bottom of the leanto
assembly so that the flange edges align along
the bottom edges of the hull, with a slight recess of
the tray. Join all three edges to hull. NOTE that
the unattached inward edge flange should be flush
with the inward side edges of hull, and will be attached
to the house side later in assembly.
17. Prepare the leanto roof base by bending back
along the bottom and sides at narrow wall perforations
and end tabs.
NOTE that corner seams will be joined in step 20.
18. Position and attach the roof 'shingles' strips by
centering between side perforations and positioning
top edges at the guide mark dashes. Because of
overlap of lower four strips, the top strip width
is  slightly narrower.
19. Continue adding additional strips until all
are in place. Top strip is aligned at top edge.
20. Join the bottom corner seams by forming corners
with straight bottom end edges overlapping tab
to perforation line, and gluing in place.
21. Apply glue to the bottom tray inward flange surface.
Position the leanto assembly on the left side of hull
and insert tabs into corresponding slots for side walls
and roof edges.
On the inside of main hull, bend the tabs outward
and glue to the backside of hull. Also apply pressure
along the tray flange to fully attach it in place.
22. Apply glue to the leanto roof panel.
Position the roof over leanto hull, insert top side
tabs into corresponding main hull slots and push in fully
so that roof edge abuts the main hull closely.
23. Apply adhesive to the inward front step 'box' surface.
Position under door to insert tabs into hull slots
and fully push in to connect step to hull.
On the inside of hull, bend the tabs down to attach.
24. Prepare the main hull lower interior reinforcement 'tray'
by bending the side walls forward, end tabs in, and . . .
. . . do the same for the middle 'tray'. 
Join all the corner seams.
25. Prepare the tea light candle cup (if you plan to
use the LED votive to illuminate the house) by
bending bottom tabs under, upper flanges back, 
end tab back, and . . .
. . . upper edge tabs forward.
26. Bend the octagon 'base' upward (to get it into
position for later attachment), then . . .
. . . form the strip into a tube to bring edges together
to overlap and form seam. Join seam.
27. Apply glue to the underside of bottom tabs, then . . .
. . . push the octagon base down into position to seat
at the tabs bend perf lines, bend tabs inward to glue in place.
Turn the assembly base down and apply pressure
on the interior all around to attach tabs and octagon fully.
28. Apply glue to the inside wall and top tab surfaces,
then bend these into the interior and glue in place
to form the cup. Make sure that they are tightly
attached to the backside of cup wall to create the space
needed to accommodate the tea light.
29. Position the cup onto the top of the middle tray
with center holes aligned.
NOTE: if preferred, TWO tea light votives can be
used to provide more light, including possibly more
into the leanto, in which case, the two cups would be
positioned side by side, covering fingertip holes.
30. Apply adhesive to the outer surfaces of middle tray,
then use fingertip hole openings to hold onto while
inserting the middle tray into the hull through roof opening.
Slide the middle tray downward gradually, maintaining
squared-up positioning, until top edge is aligned at
dash guidemarks on hull panels, a little below
the leanto 'light opening' cutout . . .
. . . as can be seen here through open trap door.
Adjust to make sure it is perpendicular, then
apply pressure all around from outside to attach 
securely in place.
31. In a similar way, insert the bottom tray into hull's
bottom opening, adjust so that bottom edges are aligned,
then glue securely in place.
32. Prepare the roof ridge reinforcement 'box' by
bending back on all panel, flange and end tab perf lines.
33. Bend end tabs back, triangle ends inward,
and form triangular tube with long flange tucked under,
and join all seams.
34. When triangle box is fully dried, apply glue to ONE
of the upper surfaces of the triangle only, then . . .
. . . position and attach to one hull roof panel,
centered side to side between roof side flanges,
and with crest edge aligned at roof panel top edge.
Apply pressure to fully secure in place.
35. Apply glue to the roof side flange outer surfaces,
(but NOT to triangle box ends)
then bend the roof section into position to align perf edges
to both angled edges of hull's side panels, and glue in place.
36. Apply glue to remaining roof panel side flanges,
and to the final upper exposed triangle box surface,
then bend the roof panel into position to fit the side
flanges inside hull walls between triangle box,
align top crest edges, etc., and glue in place.
37. Prepare the roof base by bending back the side
walls, end walls and side end tabs, and along 
center crest line. Align the corner straight edges to 
overlap the end tabs to perforation lines and complete 
the four corner seams.

NOTE that it may be helpful to achieve a strong
and accurate right angle seam to use a "press-against"
surface behind the seam such as this spatula blade.
38. Prepare the shaped roof by bending back along
the center crest line, then alternating backward/forward
bending direction going outward from center line . . .
. . . to achieve this configuration. Cut-in tabs should
all be bent back also.
39. For the first tab row attachment, identify
the set of tabs closest to crest line on one side, then . . .
. . . bend the shaped roof FULLY back to allow 
those tabs to stick out so that they can be inserted
into the set of slots on the roof base in the top row
next to the center perforation bend.
Once the tabs are inserted . . . 
. . . reverse the work to be backside up and bend
the tabs toward the roof end and glue in place
to the roof base backside.
40. Repeat the process for the next row of tabs
to insert them into the next row of slots on base . . .
. . . glue in place on backside, etc., and for
final row of tabs and slots as well.
41. At the lower roof edge, bend the final 'end wall'
segment down, align edge with edge of base wall,
and glue in place.
This image shows the profile of how the roof is shaped
with bended shapes, tabs attached in slots, and
over-roof end wall aligned with base end wall.
42. Repeat the process for the opposite side of roof.
43. Prepare to attach the roof to the house assembly
by applying adhesive to both panels of the hull's roof.
Position (centered side to side) and attach so that
roof assembly crest line and hull crest line fit snugly
together as well as roof surfaces. Hold in place until
securely attached.
44. NOTE that the over roof crest line is not attached
to the under roof at this point. To correct this . . .
. . . use a stick or equivalent to reach in and apply
glue between the two layers along the ridge(s), then . . .
. . . press the two roof layers together with ridge
perforations aligned until secure.
45. Apply glue to backside of angled fascia shape
then position and attach to the side walls of under roof,
adjust so that all edges are aligned, and hold in place
until secure. Repeat for second side.
46. To add detail and hide the tab construction,
position and attach the roof overlay strips onto
each level of the shaped roof, centering and
tucking the straight top edge tightly against the inward
perforation where tab cutouts originate.
47. Complete the final details:
A) position and attach the front door wreath; if using
an actual pronged accent brad, it will be necessary
to use a sharp point tool such as this awl to extend
the punch hole through all layers into the hull;

B) position and attach the hanging star to leanto
wall in the same manner. 
C) If using the stylized flag banner, position and attach
it with top brads pair in the same manner as wreath
(to keep bottom edge in place, consider using
double-stick tape or other 'temporary' equivalent).
48. To light the house, open back trap door,
insert turned-on LED tea light into cup holder,
then close the trap door. (NOTE that it may
be necessary to use tiny glue dots or small pieces
of double-stick tape at closure circle overlaps
to keep trap door in closed position.)
Here is the sample project with lit windows.

A final view of the completed project.

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