Saturday, December 8, 2018

Pedestal for Santa Mail 3D Box

Elevate the "Santa Mail 3D Box" project for visibility 
and visual impact by assembling and attaching 
this platform stand with pair of post legs. 
Two tier wide platform has side and top panel accents, 
with optional post gap-crossing emblem bracket 
featuring "S" monogram (for Santa). 
Box-style top platform duplicates the base "box" 
of Mail Box design, with post openings 
and interior collar supports. 
Stand post paper shapes wrap snugly around 
1.25" diameter wood dowel pieces cut to size 
for stand strength (which add weight for stability). 
Base and legs measure approx. 
5.5" tall x 7.25" wide x 4.375" deep. 
(Mail Box on pedestal measures approx. 16" tall.)

ASSEMBLY:  1. Identify and cut the shapes:
AA reinforcement support struts for platform box
(only 2 of non-tab shape is required)
BB cross brace with emblem
S main platform shape with accent overlay
T post anchor collar build up (2 sets of 8 each)
U main platform boxing strips with accent overlays
V main platform base build up (6-7) with top overlay
W second platform shape with boxing add-on strip
X post shapes (2)
Y top platform cover (for mailbox interior)
Z top platform "box"
NOT SHOWN in layout above: petal attachment collars (4)
and "aa" platform 2 support struts (2)

2. Layer and attach the base shapes, with contrast
top and bottom shapes as desired, taking care
to match up cut edges precisely. If using liquid
adhesive, it is highly recommended that . . . 
. . . this stack be pressed under a heavy flat weight
as shown here (with a different stack shape) 
to help it remain flat and straight until dry,
and avoid warping or curling.
3. Layer the collar rings into two stacks, and glue together.
Press under a flat weight as described above
while liquid glue dries thoroughly.
4. Prepare the main base shape by bending
back on the "boxing" panel perforation lines
near vertical center.
NOTE that panel with slots is TOP of platform.
Also prepare the long and short boxing strips
by bending back on all flange and panel perf lines.
5. Position and attach the accent shapes
while the platform and boxing strips are flat.
6. Position and attach each of the anchor ring
stacks on the inside of platform shape,
taking care that hexagon interior opening
edges of each are lined up precisely.
7. Join the short boxing strip to the free end of
the longer boxing strip, so that the longest segment
 is centered between two shorter segments
on each end.
8. Position the long segment on the outside center
edge of the platform main shape, align and adjust,
then attach flange under platform edge.
9. Bend the boxing ends into position to attach
each short segment to corresponding platform
edges as shown, tucking under the end tab
and attaching it to the boxing (attached) edge.
Complete attachment of both ends of 
platform boxing strips.
NOTE: bottom of platform remains unattached
at this point of assembly.
10. Prepare the second platform shapes by
bending back on panel and tab/flange perforation lines.
NOTE: some of the downward extensions may
appear to be tabs but are actually supports
and must NOT be bent.
11. Join the separate boxing strip end to
attached end by overlapping straight edge
to tab perf line.
12. Bend the boxing top tab/flanges inward, then
bend the boxing walls into position with tabs
under the platform top panel, and attach each
segment in place. As final segments are positioned,
to be glued into place, tuck tab under 
opposite straight edge and join the end seam.
13. Prepare the support struts by bending back
top and bottom flanges.
Orient strips so that center slot is upward on
one and downward on the other, then
slot the two together in an 'X' formation.
14. Position the 'X' support on the underside
of the platform next to hex openings 
(so that extensions won't interfere
with insertion of posts in subsequent steps) . . .
. . . and attach flanges in place.
15. Insert platform 2 tabs and supports through
corresponding slots on top panel of base platform
then underneath . . . 
. . . bend the tabs only back and attach in place.
Support tabs that don't have perforations
should remain extended through interior space.
16. Bend the base platform edge flange tabs inward,
apply glue, then . . . 
. . . bend the bottom panel into position,
and adjust edges to line up with boxing flanges,
as each is glued in place.
Use hex holes as access to help with attachment.
17. Prepare the post "cover" shapes
by bending back on each vertical perforation
and for each top edge tab.
18. Using the 1.25" diameter wooden dowel
as press-against shape, wrap the post shape
around to overlap straight edge over opposite
flange, snug the seam edges together so that
edge reaches the perforation line, and apply
pressure up and down the seam until secure.
Repeat to prepare two posts.
19. Measure the dowel lengths to cut to size
by bending top tabs back, pushing dowel end
to line up at top end, and marking bottom with pencil.
Cut a dowel length insert for each of 2 posts.
20. Push the dowel out of the post tube to
apply adhesive on ends, then re-insert fully
to attach tube to dowel.
21. Insert bottom (non-tabbed) end of post
through second platform hex opening . . . 
. . . and through collar to bottom of platform,
then edge back a bit so that glue can be applied
to the thick edge of the collar build up.
22. Push post back into position and brace while
glue dries. Repeat for second post.
23. To assist with post connection to platform
assembly, prepare the petal (half) collars by bending
forward along petal perforation lines,
back along vertical section perf lines.
Apply adhesive to complete backside,
then position the collar half with tall portion
wrapping around the post, short petals joining
to the top of platform 2. Repeat for the second
half collar, and for both posts.
24. Apply glue to the bottom of the platform,
then position, centered, onto top of base shape
and attach in place. HINT: it may be helpful
to place weights onto platform to assist with
pressure while this attachment is drying.
25. Prepare the top platform "box" by bending
back on all panel, flange and tab perforation lines.
Also push the hex interior tabs inward.
26. Prepare the collar platform supports by
bending back on vertical perforation lines,
bending top and bottom tabs outward.
27. Form the collar shape into a tube and
complete the side seam.
28. Position the collar over the bottom panel so that
hex opening edges align at platform hexagon
perforation array, then attach in place.
Repeat for second collar and hex opening.
29. Apply adhesive to the remaining collar tabs,
to the platform inner walls, then fold/close the box
fully and apply pressure to join box sides, collar tabs
to top, etc.
30. Position platform over top of posts and
carefully insert post tops through hex openings
(apply adhesive to hex opening tabs first)
until tabs are fully through, then . . . 
. . . bend tabs outward and glue in place.
31. Prepare the cross brace and emblem
using cut shapes shown here.
Layer the discs so that cutouts align precisely.
Layer 'S' upper overlay onto base.
Finally, position and attach disc assembly over
brace shape, 'S' centered over disc.
32. Position cross brace approx. half way up
posts, with brace strip perforations bent back
and aligning with angles of post cover on both ends.
Glue together brace surfaces to post where they touch.
33. Apply glue to the platform walls.
Insert the completed mail box hull and dome assembly
over the top of the platform, slide down until
bottom edges of both are flush, then apply pressure
to attach securely.
Here is the completed mail box on its pedestal.

North Pole Express Emblem


Detail, layered round emblem can be used separately 
or to add important identification to 
the "Santa Mail 3D Box" design front panel. 

Make the "background" colored discs "float" when
they match whatever paper they are mounted on. 
Outer disc provides a "reveal" narrow trim. 
Second disc includes faux stitch-style cut outs 
to show thru contrast outer disc. 
Inner ring holds a pair of tiny snowflakes and letters 
to spell out "NORTH POLE EXPRESS" arc letters 
(positioning guide included to assist with assembly). 
Center stylized reindeer has a slight offset base layer 
(match to "background" paper) to help with leg 
and antler visibility. 
Measures approx. 5.85" diameter. 

ASSEMBLY: 1. Identify and cut the shapes:
A ring base shape    B ring middle shape
C ring top shape (holds letters and snowflakes)
D & E reindeer and offset base)
F "NORTH POLE EXPRESS" letters
G snowflakes (2)
H lettering guide ring overlay
2. Position and attach the bottom two rings,
matching up the inner circle edges as precisely
as possible.
3. Position the letter position guide ring over
the top ring shape with inner edges lined up.
Use the north/south/east/west notch cutouts
to orient it appropriately if necessary.
Use temp tape such as masking tape to
keep the guide securely in place during positioning.
4. Position and glue each letter into the corresponding
letter portion of the guide.
Remove tape and discard guide when all shapes
have been positioned and attached.
5. Position and attach the top ring onto the previous
assembly, with offset margin maintained
at inner and outer edges.
6. Layer and attach the reindeer shape on its
offset base.
7. Position the reindeer unit across the ring opening,
adjusting so that antler and leg extensions
fall between or around letters as much as possible.
Here is the emblem shown on
the Santa Mail Box project.

Key Magical Short Dimensional


Present this "magical" key as the tool that Santa uses 
to get into each house on Christmas even 
when he can't (or prefers not to) come down the chimney. 
Fancy short key gets its dimension from 
slightly offset layers that are built up and 
stacked on front and back. 
Designed to coordinate with the "Santa Mail 3D Box" 
and "Pad Lock 3D Model". 
Measures approx. 3.75" tall 
(bit end fits into Pad Lock keyhole). 

ASSEMBLY: 1. Identify and cut the shapes:
(Step 2 will indicate quantities to cut for left & right)
A center main key body
B key body overlay
C key top "crown"   D shaft
E knob main and separate center knob
2. Use this diagram (also shown on cut file)
to cut the build-up quantities to make dimensional key.

3. Layer and attach each of the multiple shape units,
taking care to align matching edges as precisely
as possible at each step. 
(Middle units are shown here.)
Allow the stacks to dry while pressing flat with
heavy flat object.
Crown, shaft and knobs are shown here
to layer and attach.
4. Position and attach the stacks in order
onto corresponding "face" of main key base stack.
Shown at left here, is the base with middle,
crown, shaft and knobs attached,
with opposite face stacks awaiting attachment
for the opposite face.
Here is the finished key, with distress ink
helping to make it look vintage and antique.
Key can be used separately, or paired
as shown here with the Santa Mail Box
and attached Padlock 3D Model projects.

Padlock 3D Model

Shaped 3D (simulated) lock has key holes 
that align on front and back, 
with "attached" (it swivels) dimensional shackle hook 
from built-up hook layers, S emblem (for Santa), 
interior reinforcement structures. 
Sized to coordinate with "Santa 3D Mail Box
Measures approx. 4.125" tall x 2.25" wide x 1.25" deep.

ASSEMBLY: 1. Identify and cut the shapes:
A lock hull front    B lock hull back
C face plate accents front & back (2)
D interior keyhole boxing strip
E interior hull support strut
F emblem base shape and accent oval, 'S',
side wall leaf left & right
Shackle (hook( build up layers:
G center build up (4)
H & L center front & back with end tab
I & M second layer build up l & r (2 each)
J & N top layer build up l & r (2 each)
K swivel (anchor) end oval with slot, plain
2. Prepare the front and back hull shapes by bending
back on all perforation lines for panels and tabs.
(NOTE: the hull top panels were modified after
these images were taken.)
3. Position and attach the front and back accent
panels while the hull shapes are flat.
4. For Front: 
Bend back the adjacent top and side panels
to align the angled edge and corresponding 
tab perforation line to join the "bevel" short seam. 
Repeat for remaining 3 the bevel short seams.
5. Bend back the side and top edge to arrange
the straight edge to overlap the corresponding
perforation line to join the side seam.
Complete the similar 3 side seams around
the front hull shape.
6. Repeat the bevel and side corner seams
for the back hull.
7. Prepare the keyhole boxing strip by bending
forward on all vertical perforation lines.
Bend the top and bottom tabs back.
8. Form the boxing strip into a tube to wrap
the bottom flange tab around the opposite end
straight edge, and join the seam.
9. Bend the tab outward to perpendicular to
boxing wall. Identify the top panel by locating
the tiny arrow symbol cutout.
10. Place the front hull face down on work surface,
then add glue to top edge tabs, then
position the tube in position around the backside
of the keyhole, pressing tabs to attach
to hull backside. Press the sections inward/outward
to somewhat follow the keyhole shape.
11. Prepare the support strut by bending 
at the center line, also bending the flanges back.
12. Position in inverted 'V' shape around the keyhole
as shown, and glue flanges in place to hull backside.
13. Prepare the shackle build up shape.
Bend back the end tabs, then layer
and attach the center left & right shapes
back to back, keeping end tabs free.
TIP: use a flat heavy object to press the glued-up
shape (here and throughout assembly)
until glue is dries, to help avoid warping
and curling.
14. Layer and attach the remaining pairs of shapes
back to back.
15. Layer the second layer (of build up) left and right on
corresponding face of shackle, centering and
matching the straight end and slot end shapes.
16. Layer the top layers left and right
on corresponding face of shackle in similar manner.
17. Position the shackle assembly with tab end
over the circle opening, insert end through
opening, then . . . 
. . . insert tabs through slot of oval swivel.
Press tabs back and glue in place.
18. Position and attach the plain oval
over the tabs, match oval edges,
 and glue in place.
19. Position the shackle in "locked position"
with hook end over the jagged edge "slot".
20. Apply adhesive to back hull side wall faces.
Position the back lock hull  and insert
into back of hull front, sliding the large slot
circle above the oval anchor end as
the two hulls are pushed fully together.
21. Close the lock by swinging the shackle slot
hook end over the latch opening, and slide
the slot around the indent of the edge.
22. To place the padlock onto the mail box,
first align the circle openings of the door
and side brackets, then swing the shackle open
and flex slightly if necessary to insert the slot hook
end over the down through the openings.
Then swing the shackle back into position
and attach slot over opening edge.
Here is the packlock (and key) in place
on the mailbox side door.