This dapper and magical
fellow – at least the top half of him –
is presented in sturdy layers on top of
a low-relief gift card box.
Many layered details make him especially festive.
Box measures approx. 2.37” side x 3.68” tall x
.75” deep to hold a standard
gift card.
Leprechaun figure measures approx. 3.6” wide x 5.4” tall
when fully
assembled.
ASSEMBLY: 1. Identify and cut the shapes:
A figure silhouette (4-5 for build up thickness)
B front silhouette (shows thru as hands with inlay cut outs)
C eyes, mouth contrast inlays
D face overlay with eye and mouth cut outs
E shirt F cuffs & buttons
G beard overlay H mustache, nose, eyebrows
I vest, button J collar K bowtie base, overlay, knot
L hat base, band, brim & shamrock
M LID box outer panel (L) N LID box inner panel (LL)
O LID boxing strips (2)
P BASE box outer panel (single notch)
Q BASE box inner panel (double notch)
R BASE boxing strips (2)
2. Layer and glue together the figure silhouettes for thickness, taking care to align all cut edges as precisely as possible.
3. Working quickly, position the front panel on top of the silhouette stack, align all outer cut edges
as precisely as possible and attach in place.
Position and attach eyes and mouth into corresponding cut outs.
Immediately place the assembly on a flat surface and press under a heavy flat weight such as this thick
book, with something else heavy on top, and leave
in place until thoroughly dried - requires several hours
or overnight. Pressing will help minimize curling or
warping of the liquid glued-up shape.
4. Assemble the hat component by . . .. . . layering and attaching the band in place, then . . .. . . overlaying the brim at lower edge, then position and attach the shamrock accent.
5. Position (center) and attach the vest on top of the shirt with upper corresponding edges aligned, then . . .
. . . position and attach the button in the cut out window.6. Prepare the bowtie by layering the front shape with "fold" cut outs on top of the contrast base
shape (shown upside down here - ooops)
and knot on top.
7. Assemble the face unit.Position and attach the beard where it fits along the bottom of the face shape, and the mustache
centered above the mouth cut out.
Then position the nose abutted next to the mustache at the top shape where it fits, eyebrows over
the eye cut outs as shown.
8. Finalize the torso assembly: A) position
the shirt/vest unit over the bottom portion of
the silhouette shape where it fits and attach in place;
B) position the collar shape over the vest, centered and with the top edges aligned with shirt/silhouette
edges and attach in place;
C) position the face/beard shape over the assembly matching the side "ears" and beard edges of
all layers, then attach in place;
D) position hat at top of assembly where edges match, and attach in place; E) position and attach
bowtie below the beard bottom tip.
BOX ASSEMBLY
9. Click on this LINK and follow the "Box Assembly" Steps 1-4, then return to this post for a slightly
different assembly of box LID and BASE.
10. Identify the inner BASE "floor" shape by finding
the double notch cut out along one end edge.
Prepare the BASE boxing shape as shown.
11. Bend the boxing strips tabs inward at right angle, then apply liquid on the inward surface.
Insert panel inside the boxing frame and . . .
. . . push fully down into position, allowing the boxing
to shape itself around the panel. Apply pressure all
around edges to attach to boxing tabs.
Be sure to make sure that the long or short side walls
do not bow outward at all, but stay tight and
parallel to the panel cut edges.
12. Reverse the BASE box.
Apply glue around the boxing edge, with
some in the center as well.
Position outer panel over the bottom and center
it so that all outer edges are even.
If possible, consider placing the BASE shape on a flat
surface with something heavy to press down the panels
to assist them to attach fully to boxing tabs, such as
this wood cut off, or several same-height thread spools
placed along edges and inside boxing, with something
else heavy pressing them down. Leave pressing tools
in place until seams are fully dried.
13. Repeat the assembly process for the LID,
using the interior panel with 'LL" and the
exterior panel with 'L'.
14. Apply adhesive (quick-grab suggested, such as
Fabri-Tack) to the outer panel of the LID, then
position it behind the torso assembly . . .
. . . where side edges and bottom edges of LID
will be concealed by torso edges.
If the bottom end of the LID box is placed
near the bottom of torso, it will assist the box
to stand when filled and fully assembled so
that it can be used as a decoration as well.
15. To close the gift card box, place the card
inside (possibly held in place against BASE floor
with a temp hold sticky dot, etc.), then fit the LID
over the top of BASE. That is, BASE walls should
fit inside of LID walls.
Push LID fully down into place.