Sunday, July 18, 2021

Twin Popsicle 3D Box Gift Card Holder

 
Re-create this classic twin popsicle
(in your recipient’s favorite “flavor”) 
as a slider box which opens to reveal 
a gift card held in place with interlocking slot arms. 
Layered stick shapes are glued together 
for a realistic presentation
Box project measures approx. 3.25” wide x 6.5” long 
(including sticks) x .84” deep when assembled and closed.
 Plain liner insert included as alternative for treats 
or other appropriately sized gift.

ASSEMBLY: 1. Identify and cut the shapes:
A slider main base   B slider sides & walls boxing walls
C slider front wall and wrap compartment
D  sticks opening interior cover
E gift card carrier insert (1-3 layers
for thickness) with optional securing arms
F stick shapes (2 sets of 6-7 ea; see Step 2)
G stick front/back (2 sets of 2 ea)
H stick layers test window with test strips
I sleeve hull back panel   J sleeve hull front panel
K sleeve hull side/top walls boxing strip
L hull front accent layers: whole base, 
front with windows, highlights
2. To determine how many stick "core" strips to cut
to fit snugly through the cutout windows in slider bottom,
conduct a test by layering . . . 
. . . test strips into a stack, then inserting through
the test window. Selected card stock will affect how many
fit. Likely 8 strips will fit best; but 6 or 7 are also possible.
Once the quantity is determined, subtract 1 each for
stick front and back (2 total), then use that new total
for core quantity. Cut two sets.
3. Prepare the side walls boxing strip for the main hull
by adding curl to the strip at the multiple notch areas,
using a rod-like tool such as this wooden dowel,
applying fingertip or thumb pressure as the card stock
strip is drawn across the tool. NOTE that the dash marks
that define the segments of the rounded portions
of boxing strip (at ends of multi tab segments) should
be considered as guide marks and 
NOT bending perforations. 
4. Add 'M' folds at the center - valley fold at center
perforation, mountain folds on each side.
5. Bend the mini tabs and all of other tabs
back to perpendicular.
6. Position the 'M' bends at the top center edges
of the hull BACK panel, with straight panel edges
aligned at tab perf bends, and join in place.
7. Align the next segment of the wall boxing strip
along the straight portion of top edge to one
side of center, and shape the curved multi tab
length around the corner. Use the guide marks
on the panel and on the boxing strip that define
the corner curve to align edges accurately,
and glue in place.
To help secure the seam, invert the assembly face down
on flat work surface and apply fingertip pressure along
the inside where tabs are attaching. 
8. Continue to align and join the long side length
of boxing strip at the panel edge.
9. Repeat the past two steps to complete the opposite
side of hull-to-back boxing seam.
10. Repeat the steps to position and attach
the FRONT hull panel to the hull walls boxing strip.
It may be helpful to use a flat tool blade (as well
as fingers) inserted into the windows to adjust
and apply pressure along the hull-to-walls seams.
11. Prepare the front accent assembly by first
positioning and attaching the outline/windows panel
on top of the hull panel, will all outer edges aligned
as precisely as possible.
Next, position the two highlight accents . . . 
. . . inside the left edges of each window, and
attach in place.
12. Position and attach the front accent assembly
onto the front of the hull, with outer edges aligned.
13. Repeat the prep for the slider boxing strip, by
adding curl to the two rounded corner segments where
multiple tabs . . . 
. . . fall along only one side edge (this is one way
to tell the slider boxing walls from the hull boxing).
Also bend the center perforations in the 'M' 
configuration as for the hull boxing.
Bend the attachment edge tabs, and the rim and
end tab back.
14. Identify the end tab symbols (tiny triangle or circle)
in the slider boxing and the bottom end panel,
which show where the two shapes attach.
Position the slider bottom panel as for the hull panels
at the center top to attach tabs at 'M' bends, then . . . 
. . . then continue to position top segments, rounded
corners, and log side segments to bottom panel . . . 
. . . until first one half of boxing strip and then second
half are aligned and joined in place.
15. Prepare the bottom end panel by bending
back on all the panels, tabs and flanges,
except bend forward at the rounded side tabs
and the interior cross flange between those tabs.
16. Position the exterior long flange along slider
bottom edge, and the side symbol-containing tabs
tucked inside the bottom edges of boxing strip,
adjust and glue in place.
17. Near the bottom panel, two shorter side tabs
are NOT rim tabs, but should be left 
in perpendicular position. 
Bend the remaining rim tabs inward and glue 
in place to inside of wall.
18. Bend/wrap the bottom panel extension toward
the slider interior. Top-most side edges should
align and attach to the no-rim tabs. Apply . . . 
. . . adhesive to backside of top flange, and 
rounded side tabs, as well as boxing side tabs
that extend under bottom panel. Then . . . 
. . . fold/wrap the panel into position, with . . . 
. . . long flange cut edge aligned at 
dashed guide line on base panel.
One way to assist interior cross wall to be secured into
upright perpendicular position is to use a squared
block to push the wall and tab angle into position.
19. Begin stick preparation by bending top tabs back
on front and back stick shapes.
20. Position the core stick shapes into a stack
and glue each together. Take care that ALL cut edges
are aligned as accurately as possible.
Also position the tabbed front and back stick shapes
onto the front and . . . 
. . . back of core stack, 
with side and rounded bottom edges aligned
as accurately as possible, 
and glue in place.
Press the assembly under a heavy flat weight
while glue dries, to avoid warping and curling,
and ensure that the shape stack remains flat.
(This may require a few hours.)
Prepare two sticks.
21. Apply glue to the outer surface of tabs, then
insert end through interior slot, through closed space,
and . . . 
. . . out the opposite slot. Push completely into place
so that tabs rest against the wall surface . . . 
. . . and attach in place securely.
22. Apply double-stick tape to the backside
of the "cover" rectangle, then center over the panel
to conceal stick tabs, and attach in place.
23. Prepare gift card holder insert by layering
the insert shapes into a stack with ALL cut edges
aligned as precisely as possible, and gluing together
Press flat under heavy weight until dry.
24. Gift card insert can be inserted as is into
the slider compartment . . .
. . . with gift card inserted into the window
(consider securing with temp sticky dot
or 1" length of double sided tap).
Or, if preferred, position and attach the interlocked
and centered arms over the middle of the insert,
wrap ends to backside and secure there;
or trim excess and attach at insert edges.
When gift card is positioned, arms can be
slid open to allow card to be removed.
This image shows the arms-secured card in place
as the slider is inserted into the bottom opening
of main hull.

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