Sunday, September 27, 2020

Frankie 3D Display Box

Not-too-scary Halloween decor doubles as a gift box 
with LID and BASE boxing compartments that 
fit snuggly together.  Built-up layers provide strength 
and substance, with separate “underside” layers with 
positioning guidance for boxing assemblies. 
Loads of details “bring Frankie to life”: 
shoe uppers and soles, shirt with batty buttons, 
craggy hands, highlighted eyes, head side bolts, 
flat-top hair, toothy grin, cheek ovals and scars. 
Measures approx. 8.25” tall x 4.25” wide with 1” deep boxing. 

INSTRUCTIONS: 1. Identify and cut the shapes:
A LID front panel shapes (3-4) to layer for thickness
B LID inner layer with guide marks
C LID boxing base shape
D LID boxing strips
E BASE bottom panel shapes (3-4) to layer for thickness
F BASE inner layer with guide marks
G BASE boxing base shape
H BASE boxing strips
Identify and cut the 'character' front panel shapes:
I pants decor shape    
J pants foundation layer extension (doesn't show)
K main shirt front   
L eyes white contrast panel with nose wedge contrast
M head foundation (doesn't show)
N arms, sleeves, shirt shoulders for left & right
O bat button shapes (2 buttons @ 4 each)
P shoes 'upper' foundation plus soles
Q face details: bolts and collars; cheeks, ear underlays
R flat top hair, long scar, eyebrows, eye blacks & whites,
small scar
S smile with teeth underlay
2. Identify the LID front panel shapes which have the 'L'
cut symbol; also identify the BASE shapes which are
reversed from LID with 'B'.
3. Position and attach the front panel shapes to create
a thick panel for box front, taking care to align ALL cut edges
as precisely as possible.
4. Identify the LID inner layer that has boxing shape
positioning guide marks offset approx. 1/4" in from edges.
Also NOTE that this shape is reversed from the outer layer.
Position this on the bottom of the front layer stack
with ALL edges lined up, and glue in place.
5. Immediately position a heavy flat object (such as
this planed wood plank, or a large book) over the top of the stack
to press flat while the glued-up stack is allowed to dry
completely (for a few hours). 
6. Repeat Steps 2-5 for the BASE build-up layers.
7. Position each of the four bat button shapes for a button
into a stack, and glue together, matching all cut edges
and hole openings, then press flat under a heavy object
until thoroughly dry. Complete two buttons.
8. Complete pre-assembly for components of the character
front decoration, and press under flat weight if possible:
A) layer optional eye highlight show-thru circles behind pupil;
B) position and attach bolt collar strips on top of bolt shapes;
C) position smile on top of the teeth/smile shapes;
D) position and attach sleeve and sleeve cap on top
of arm shapes for left and right assemblies
E position and attach shoe sole strips on bottom of shoes
Here are the components assembled:
9. Prepare the pants/foundation layer by
abutting the upper torso/head shape above the pants
shape with straight edges aligned, sides even,
and secure with small pieces of cello tape.
10. Prepare to position and attach the shirt main shape,
head foundation shapes with eye and nose contour
show-thru shapes . . .
. . . then position and attach the head shape with flat-top
and bolt shapes aligned with pants foundation,
position shirt shape below (with puzzle notch interlock)
and attach, then fit and attach eye show thru and nose
contrast in the recess that remains. Press under flat weight
while adhesive dries thoroughly.
11. Prepare to assemble the head:
A) attach hair where edges match
B) attach ear contrast shapes behind ear cutouts
C) attach left and right bolt assemblies
D) position and attach eyebrows, scars and smile.
Press under a flat weight while adhesive dries.
12. Position and attach shoe units onto assembly.
13. Position and attach the head assembly on top of
the body assembly layers where upper edges align, then . . .
. . . position and attach cheek ovals into recesses,
and eye units into eye socket recesses.
14. Position and attach character assembly
onto the LID stack front; press under weight until dry.
15. Become familiar with the identification system of
the boxing strips. Shapes have cut symbols of circle,
triangle or 'X' on end tabs and edge tabs to help identify
which strips are for LID boxing (single) 
or for BASE boxing (double), and . . .
. . . which strip ends join.
16. Prepare each strip by bending back top (LID) or
bottom (BASE) attachment flanges, end tabs, and
vertical perforations. It may be helpful to re-direct
the vertical bends so that the strips echo the boxing shape
edges, as shown below for LID.
This diagram shows the LID and BASE shapes with
the angle location where the strips will join, identified
by the symbol shapes cut into tabs.

NOTE that the L & B shapes are reversed to be
face down for assembly.
17. Position the lower/side boxing strip at the bottom edge
of the LID boxing shape, center edge along boxing segment,
then glue in place.
18. Position the next few tabs and edges around the feet
shaping edge so that strip segments align with edges,
and glue each in place. NOTE that there is a small
amount of allowance margin at main shape edge
that may need to be "averaged" or adjusted as strips
are positioned and attached.
19. Continue to position, align and glue tabs along edge,
applying fingertip pressure to firmly attach strip.
20. Position and attach the next strip (match symbols)
by overlapping straight edge over end tab to perforation line.
21. Continue to position and attach the boxing strip
around the top of boxing shape.
22. Position and attach the opposite side strip at end,
then position and attach around the side edge,
pausing before the final edges and tabs are in place . . .
. . . so that the final end tab can be slipped behind
the adjacent straight edge to align and join that seam,
while at the same time positioning final segments
to complete boxing attachment.
23. Position the boxing assembly at the backside of
the front built-up stack, using the guide assist
with placement, then attach in place.
(A flat weight such as a book placed on top of boxing
will assist with attachment.)
24. Repeat the boxing attachment of Steps 17-23
for the BASE.
25. Position and attach the bat buttons at shirt
center, tying with cord knot, bow and streamers
as desired, or . . . 
. . . insert a length of sheer ribbon front-to-back
through holes with trimmed tails as was done
for this sample, before attaching.
26. To close the box, fit together LID (outer walls)
and BASE . . .
. . . then slide completely together.
Here is the completed box.


  1. I love all of your designs, your style is fantastic! It's got that vintage vibe to it which I love!

  2. Thank you! So kind of you to take the trouble to send a nice comment!

  3. I LOVE this design and can't wait to work on it today! The papers you used look great, did you 'age' the edges with ink? If not, how did you get that marvelous look? Thank you

  4. Yes, I like to "distress" the edges with Tim Holtz pumice stone ink.