Wednesday, July 28, 2021

Wheelbarrow 3D Container

Vintage-style garden transport features a ‘bucket’ 
large enough to hold silk posies for a table centerpiece 
component, a considerable volume of loose treats, 
or a special cupcake baked treat. 
Sturdy components allow for repeat use and 
between-seasons storage. Dimensional (non-functional) wheel 
is designed to optionally fit one of the “Gadget Gears” 
metal “hubs” from Tim Holtz collection 
(card stock look-alike component shape included in cut file). 
Dress wheelbarrow up with purchased miniature flowers
 or other adornments. 
Finished size is approx. 9” long x 3.75” wide 
x 4.125” tall when assembled. 

ASSEMBLY: 1. Identify and cut the shapes:
A barrow "bucket" hull with interior accent shapes
B left & right exterior side trim with build-up shapes (4 ea.)
C center exterior front trim with build up shapes (4)
D undercarriage reinforcement with leg extensions
E interior reinforcement tray
F undercarriage handles with wheel yoke extensions
G & H handle beams left & right with build up (6-7 ea.)
I axel square tube (tube will be wrapped around
a cut-to-length piece of .125" diam. wooden dowel)
J legs cross beam (7-8 build up per slot fit test)
K slot with test strips to determine layers quantity for J
N & M left & right legs build up (6-7 ea. of main shape;
1 ea. of face shape.)
O wheel boxing strip  P wheel sides bases (2)
Q wheel "covers" with spokes detail (2)
R wheel accent overlays (2)
S wheel 'gear' accents (card stock or metal)
If desired, consider adding the metal wheel accent
from the set shown here (use 2 packages if
using matching gear on each side of wheel; see S above).
2. Use the slot and strips to test how many leg cross beam
shapes will be needed for a snug fit, with strips cut
from the cardstock planned to cut cross beam shapes.
Stack the strips, then see how many will fit snugly
through the slot, adding or subtracting as needed.
Once the quantity needed is determined,
cut that many from selected card stock.
3. Begin the assembly process by layering, gluing together
the several components so they can be thoroughly drying.
A) layer and attach leg cross beams, taking care that 
ALL cut edges align as precisely as possible then . . . 
. . . press flat under a heavy weight such as this thick book.
(Press ALL glued-up shapes for several hours until
completely dried - several hours or overnight - to help
keep them flat, avoid warping or curling.)
B) left and right handles, taking care that ALL cut edges
align as precisely as possible, including axel cutout holes.
C) left & right legs stacks with . . . 
. . . top shape the face shape that includes the stud
accent placement circle cutouts.
D) trim shapes; sample is constructed with multiple
shapes plus decorative card stock face layer
4. Prepare the barrow 'bucket' by bending back on
all perforations for panels and flange tabs.
5. Position the middle and front interior accent shapes
on the backside/inside bucket surfaces;
retain the side accent shapes until later in assembly
when the corner seams have been completed
(see Step 12).
6. On the outside of hull, position and attach the trim
stacks along the corresponding edges. 
Press the hull assembly under flat weight until dry.
7. Prepare the undercarriage by bending forward along
the handle extension perforation lines (shape in image
is shown from backside). 
8. Position and attach corresponding handle stack assemblies
onto outer surface of handle extension when bent back.
Press flat under weight until dry.
9. Bend leg extensions on hull undercarriage reinforcement
forward, then . . . 
. . . position and attach the inside "cover" short leg shapes
onto the extensions, taking care to match up
the slot cutouts as precisely as possible.
Make sure that the leg extensions can properly
stand into perpendicular position (no interference 
at bend edges). 
10. Position and attach the reinforcement over
the center portion of hull within perforation lines.
Press flat until dry.
11. With handles bent back in finished position,
apply glue to the backside, also along the thickness
edge of handles (ONLY where they will attach to
hull underside) then . . . 
. . . position onto hull assembly underside with
shaped front edge aligned at hull front panel
perforation, also centered side to side so that
hull side perforations are parallel to handles,
and glue in place. Consider propping legs in
upright position, applying appropriate weight
to help with attachment, until thoroughly dry.
12. Bend the hull sides and front panel together 
to overlap straight edge to tab perforation and
glue seams.
(Position and attach interior side accent shapes now.)
13. Extend attached leg into perpendicular position
then position and attach corresponding leg stack
to extension and adjacent hull wall, taking care
to align slot and other cut edges precisely.
14. Insert leg beam through leg slots across bottom
of hull assembly, adjust positioning so that legs
remain perpendicular, beam centered between, then 
apply glue to the inside of slot edges and attach beam.
15. Prepare selected interior reinforcement tray by
bending back on ALL perforation lines for side walls
and center panel, except bend the curved corner tab
at back forward.
16. Bend walls into position to form corners with tabs behind 
front or back walls, join four corner seams. 
17. Apply glue to outer face of side walls, underside of
back flange, then position tray into bucket bottom, 
attach side walls and back flange to adjoining surfaces.
NOTE: alternative tray to secure bottom of cupcake
 is assembled in same manner.
18. NOTE that the strip end tab is NOT folded back;
perforation cuts there are for alignment.
Prepare to assemble wheel by first adding back curl
to boxing strip, then . . . 
. . . bending multiple tabs back and pinching along
perforations to create consistent fold edge.
19. Form the strip into a ring to bring ends together,
align straight edge at cut marks, and glue seam.
20. Apply glue to the inside undersurface of first set
of multiple tabs all around, then . . . 
. . . slip the first wheel ring inside the boxing ring . . .
. . . and press down into position so that the multi tabs
adhere to the outside of wheel ring. Apply pressure
with fingertips all around ring edge to ensure . . .
. . . that each of the multi tabs attaches properly.
21. Bend final multi tab edge back to straight position,
apply glue to the underside of tabs, then . . . 
. . . slip second wheel ring inside assembly . . . 
. . . to allow tabs to be wrapped over edge
and attached to ring face. 
NOTE that the assembly should be inverted onto
flat surface, then fingertip or thumb inserted through
opposite side hole to apply pressure all around edge
to attach multi-tabs to second wheel ring, as was done
for the first side. 
22. Prepare the wheel axel cover by pressing the center
cross cuts and square perf cuts inward, using
the tip of a narrow tool such as this spatula handle.
NOTE that the tiny triangle tabs are intended to
be glue-attached to axel surfaces in final assembly.
23. Position and attach the first wheel cover to one face
of the wheel assembly, then position and attach
the second wheel cover, taking care that the spokes
and axel square hole line up exactly.
NOTE that as the cover is positioned, rotate it so that 
the bottom seam of boxing aligns in perpendicular
position to the square "bottom" edge of axel hole.
(While other alignment is possible, NOTE that spokes
of cover are parallel to wheel bottom, in line with
axel square hole, in this optimum arrangement.)
24. Position and attach the smaller accent wheel
and the gear shaped accents on each side of wheel.
(In place of card stock gear shape, position
and attach - with appropriate adhesive - 
the metal Tim Holtz gear.)
25. Prepare the axel post strip by bending back
on all perforation lines. NOTE that angled ends
of one side segment indicate the side flange tab.
26. Wrap the axel strip around the .125" diam. dowel
with straight side edge overlapped across side flange
to align at first perforation line, and glue seam.
Use the dowel as a "press-against" surface.
More the dowel tip down to align at end of tube,
bend top tab down into place, then . . . 
. . . mark the opposite end of tube on dowel
as cutting length. Remove dowel and cut at mark.
Re-insert cut dowel piece, apply glue to dowel ends
and bend end tabs into position to attach in place.
27. Test the axel fit into wheel holes, if desired,
taking care that triangle tabs bend back into
wheel interior.
Attach wheel assembly to "yoke" handle extensions
by inserting axel post through one side, then
pass through wheel axel openings, then
across and through opposite yoke opening.
Adjust to center post between arms, with wheel
centered, then slide components slightly to
apply glue to axel, then reposition to attach
arms and wheel side walls in place.
Apply decorative studs to legs at positioning holes.
Here is the completed wheelbarrow container.
If desired, decorate hull exterior with purchased
paper or silk/poly flowers, buds, ribbon, etc.
A nosegay of flowers can also be placed inside
the bucket as decoration.