Hat Colonial 3D Tri Corner Box

Iconic patriot head gear has eight-sided crown “dome” 

with round brim that is “curled” at side front edges 

to reach up and attach to dome sides. 

Edge trim adds accent, along with simple colored cockade. 

Octagonal short “base” can be inserted under the brim 

to convert the hat to a container, with cross straps 

that hook together to keep the base in place. 

Use as display for July Fourth decor, 

as a wreath or centerpiece decoration, or box “lid”. 

Measures approx. 4.25” front to back x 4.75” side to side 

at widest point x 1.625” tall at crown center when completed. 

(Size is coordinated to hang from the final ‘A’ letter box 

of “AMERICA 3D Letter Box Display” design.)

ASSEMBLY: 1. Identify and cut the shapes:

A brim   B crown wedges (8)

C brim under trim    D brim over trim (3)

E cockade scalloped disc, circle star

F cockade pleated "ribbon"

G box base main shape   H box base add-on wall strip

I box base octagon reinforcement  J cross straps

2. Prepare the brim shape by bending the opening

flanges back.

NOTE that the punch holes for brads or as guide marks

will orient toward the straight sides of the octagon

opening differently for center back and for sides.

Pointed at in this image are the octagon back edge

and the hole punch.

3. Further prepare the brim by rolling the three extensions

back for 2 inches or so next to the opening using

a dowel or other smooth rod tool. 

This will assist and allow

the brim to bend upward gently later in the assembly.

TAKE CARE not to apply bends - only curl.

Add the curl to each of the three "corners" or lobes,

keeping the curling tool parallel to the curved brim edge

where the punch hole is centered.

4. Add a corresponding back curl to the brim trim

at all three lobes.

5. Prepare to attach the brim under trim to

the FACE side (which will be the downward side -

or underbrim surface) by identifying the tiny cuts

that will indicate the center of each lobe.

Then apply glue to one section, and position so that

the guide cut aligns directly centered above

the punch hole, and with outer edges aligned,

and attach.

Repeat for the remaining two lobes, shaping the trim

to match the curl of the brim edge previously added.

6. Use the rod tool to add a little back curl to

the ends of the shorter three upper edge trim shapes.

Position and attach these trim shapes on

the backside or upper surface of the brim,

centered along the area between the lobes

(half of the trim shape is hidden by left hand here).

7. Immediately after the trim shapes are all in place,

assist the brim into its desired lobes-up configuration

then allow trim to dry so that shaping is "locked in".

8. Prepare the eight crown wedges by bending back

on all cross perforation lines and side tabs.

Also become familiar with the designated order of

the wedges which is essential for alignment of

brim punch holes with wedge punch holes later.

9. Begin to attach the first four wedges

(center back #1 and 2-4 as designated in cut file)

 by lining up two side by side with the second tier aligned,

straight side edge of the left shape overlapping

the tab of the right shape to perforation line.

Adjust up and down so that cross perf lines match up,

then join the seam.

10. Move downward to bend the bottom tier edges

into position with straight edge exactly along the tab

perf line, and join this seam segment. Then . . .

. . . move upward to bend, overlap, adjust

and join the top tiers in sequence until the whole

seam is completed.

11. Position and attach the third wedge in

the same manner, then the fourth to complete

a half dome.

12. Complete the second half dome with remaining

four wedges.

13. Prepare to join the halves by lining up and

overlapping the straight half edges over

the corresponding tabs, opposite. Then . . .

. . . apply fingertip pressure along top two segments

first, then work downward to opening edges to

align, adjust and join segments all along seams.

14. Position the dome over the top of the brim

(which has the FACE side downward) with the opening

tabs under/inside the dome.

Adjust the rotation of the dome so that each tab

aligns with a facet of the dome, then blue each

in place.

NOTE that it may be helpful with attaching each

segment of the dome-to-brim seam by inserting

finger into dome while also pressing from the outside

with a narrow flat/straight surface such as this

narrow Silhouette scrapper tool.

15. If preparing the tri-corner hat as a box,

prepare the cross straps by bending back at

end tab perforations, hooking the rounded ends,

then positioning at the side center octagon edges

inside the dome.

Align perf bend at brim/dome edge and glue in place.

17. Prepare the cockade "ribbon" shape by bending

perforations in accordion configuration as shown

(center pair of folds as "mountain" and outer pair

as "valley"). Fold the pleats flat and apply glue near

bottom edge between folds on front and back

to secure flat edge along bottom.

18. Assemble the medallion by layering and centering

the plain circle on top of the scalloped circle,

with the star on top.

19. Determine how you want the cockade to look

as far as star north/south orientation, then insert

the ribbon edges under the medallion approx. 

a generous 1/8" and glue to attach.

20. Bend each lobe up into final position to align

the brim and corresponding wedge holes, then

apply glue between around one of the holes

to attach the two surfaces. Insert and attach

decorative brad to adorn and assist the attachment.

21. Position and attach the cockade onto one of

the brim's sides as shown.

22. For the hat's box, prepare the main box base

and add-on walls shapes by bending back on all

perforation lines for wall segments, tabs, and

upper wall extensions.

23. Position the extension left straight short wall edge

at the main base's similar extension right end tab,

with edge overlapping the tab to align exactly

at perforation line, adjust top to bottom, then join seam.

25. Bend the octagon floor portion upward to allow

the wall strip to be formed into a ring to bring 

the free end tab to be inserted and attached under

the straight wall edge of the attached segment,

then join seam to complete walls ring.

26. Push the floor octagon down into place so that

edges slot into position along each of the tab perf lines.

Bend each tab inward and join to the floor underside.

Apply fingertip pressure from the inside to secure

each seam segment.

27. Position and attach the reinforcement shape

to the underside of box to conceal tab construction.

28. To close the box, insert box base into the underside

opening of tri-corner hat . . .

. . . then bend the cross straps

into position and hook to latch into place.

Truck Treat Box Narrow with Bunting

 

With details created with cutouts and overlays, 

classic truck’s flat front and back panels holds 

a narrow treat box between. 

Container opens at back end to fill with loose treats such as 

jelly beans or other dry candy. Gift the container alone, 

or add patriotic half-circle bunting decoration. 

Truck “fence” can also display a Christmas wreath 

or other season element as desired. 

Build the box, fit the boxing tabs around box front and back 

panels, and then attach between front and backs. 

Measures approx. 8” long x 3.8” tall x .75” deep. 

Includes alternative top boxing strip with ‘AMERICA’ 

line cut lettering and star cutout for a fun Fourth of July 

(or other patriotic) holiday gift, or use as free-standing 

classic vehicle decoration. 

Size coordinates to “AMERICA 3D Letter Box Ensemble” 

design or can be use as a dimensional full container 

element or as front panel alone. 

NOTE: For the classic truck card version, follow

the general assembly steps, omitting thickening build up &

container steps, then refer to the design description

in the Silhouette America online store.

ASSEMBLY: 1. Identify and cut the shapes:

NOTE: "front" will indicate the truck panel that

faces left; "back" will indicate the truck panel

that faces right. Cut one set for front, one for back.

A "front" main truck shape  B "front" truck base

 C wheel set: tire, whitewall, hub cap & button (4 sets)

D fence base (1-2)    E fence slats (2-3 each of a pair)

F door handle   G bed rim strip

H bunting assembly: 

4 half circle shapes plus header strip

I "front" base (3 for build up thickness)

J "front" inner layer with position markings

K "back" base (3 for build up thickness)

J "back" inner layer with position markings

M container front with closure wall & tab

N container back (NOTE fingertip access

openings have been added to the shape)

O & P container boxing strips to join

2. Layer and glue together the front and back base

stacks, taking care to align ALL cut edges as

precisely as possible. 

3. Identify the inner front layer by locating the container

corner markings, then . . .

. . . position on the backside of the front stack,

align all cut edges as done previously, and attach.

Immediately press the stack flat using a heavy flat

object such as this large book volume, possibly with

other heavy objects on top. Allow to stay pressed while

the stack thoroughly dries, for several hours or over night.

This will minimize warping or curling.

4. Repeat the assembly of the back base stack.

5. Prepare the fence slats in a similar manner,

positioning the 2-3 strip shapes in a stack with

all cut edges precisely aligned, and glue together.

Then position each of the pair for first set onto 

the fence base (stack and glue fence first), then

press flat under a weight until dry.

Repeat for the second fence with slats.

6. Prepare the two pair sets of wheels in similar manner:

stack the three largest circles by aligning

the center punch circle, then position and

attach the center button over the punch.

Press under a flat heavy weight until dry.

7. Prepare the two bunting assemblies by stacking

and joining the four half circles with top straight edges

aligned and center notches matched. Press until dry.

If desired, use a straight edge aligned at the scallop

"valleys" of the layers to simulate folds.

8. Position the header strip, centered, across the top

of the assembly and glue in place.

9. Position and attach the back main truck over

the back truck base with corresponding edges aligned,

including window opening. Repeat for the front set.

10. Position door handle strip into the recess of

the front and back assemblies. Position and attach

the bed strip along the top edge of the bed portion

of the layered assemblies.

11. Position the front or back truck body assembly

over the layered and cured base to which it corresponds,

with narrow offset border at edges, window openings

matched exactly (no offset) and glue in place,

leaving the bed rim area unglued until . . .

. . . the bottom "stick" ends of the fence assembly

can be inserted under the truck body layers . . .

. . . then adjust the fence to be even with bed rim trim end.

12. Position and attach in place the wheel assemblies

into the wheel bay spaces with similar offset margins

to the other truck body edges.

13. Position and attach the bunting assembly

at the top of the fence top slat strip.

14. Become familiar with the container boxing to

determine the ends that will be joined to create one

long boxing strip. Shown here, the top strip's end tab

includes a tiny circle cut out symbol which will join

to the lower strip's end top tab which includes

the same symbol.

15. Prepare the strips by bending the side tabs back,

and the cross perforations back as well.

16. Position, align and join the strips by overlapping

the plain end across the circle cutout end tab to

perf line, and join seam.

17. Complete a test arrangement of the strip around

the back container panel to re-bend some of the perf

lines to match.

18. Apply glue along the top (long) boxing edge flange,

then slide the back panel inside the boxing, align

top panel edge and boxing to flange, and glue top seam.

19. Continue to tuck the boxing around the back panel

edges, attaching flanges in place all around to

back opening.

20. Insert the front panel so that panel edges are

under the remaining boxing flanges, and work around

to attach in place. NOTE: the openings in back panel

will allow fingertip access to assist with this.

At the back end of assembled container.

the final wall and tab will act as closure

once contents are inserted.

21. To assist with the opening of the container's door

flap, position the narrow strip tab at the center of

the closure flange and glue in place. When the container

is filled and closed, the strip should still extend outward

so it can help pull open the flap.

22. Locate the positioning guide marks on 

the underside of the "back" truck assembly, then . . .

. . . apply quick-grab adhesive to the container face

that will attach there. Position, adjust to align

with upper corner guide marks and side edge marks,

as well as . . .

. . . ensuring that the container bottom extensions

are even with the base wheel area bottom edges.

Then apply pressure until secure in place.

23. Repeat the process for the other truck assembly

to position, adjust and glue in place to container face.

24. Check the tab to assist with container opening

and trim shorter if desired.

This image shows how the tab will help with opening.

Here is the container, completed.