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ASSEMBLY INSTRUCTIONS FOR THE LARGE HEX HAT BOX | |
BEFORE YOU GET STARTED: 1. Clear a work area- a sturdy table top about 3' by 3' works well. A piece of fabric laid on the on the top of the table protects the outside surface of the plastic, but if you work carefully -lifting the parts instead of sliding them- a clean uncovered table top surface is sufficient. |
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2. To avoid fingerprinting, wash and dry your hands well before starting assembly. | |
3. Assembly should be done at room temperature or above. The plastic sheet folds much easier when it's warm, the handles snap on easier when there room temp. or warmer. | |
4. The textured (lined) surface of the plastic will become the inside of the hat box. All printing is done on the smooth outside surface. | |
5. The embossed lines on the smooth surface are called "score lines".All score lines should be folded over before starting assembly. Folding over the scores, even repeatedly, does not weaken the plastic. | |
6. To assemble a hat box, first fold over the scores. Next fit the handle. After the handle do the rivets and finally thread the cord. Let's do it ! We will do the bottom part of the hex box first. | |
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With the textured side of the sheet up fold over all the scored lines. When you fold, it will be textured surface touching textured surface. Being folded over in this picture is the 1 1/2" side tab. This side tab is on the inside of the finished box. The textured surface is up in this picture. |
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Fold over the side walls.
The textured surface is up in this picture. |
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Flip the plastic sheet over so the smooth surface is up. Reach underneath and push the handle flanges in. The smooth surface is up in this picture.
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Push the handle over the handle flanges as far as you can. The handle can be "set" by tapping each side of the handle with a small block of wood.
The smooth surface is up in this picture. |
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Sometimes a firm hand can "set" the handle.
The smooth surface is up in this picture. |
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Some handles snap together from the sides. Fit these on the handle flanges and squeeze the two sides to complete assembly.
The smooth surface is up in this picture. |
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This is a picture of the SST-2.5 black fastener. You will need 18 sets to assemble a "Large Hex Hat Box". The bottom part is the female half. The female half will be on the outside (smooth surface) of the hat box. |
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From underneath push the female part of the black fastener into first the side wall and then into the 1 1/2 inch tab. (The 1 1/2 inch tab will be on the inside of the hat box.) Now push the male part of the black fastener into the female part. The textured surface is up in this picture. |
Now let's do the hat box top.
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Just as before all the scores must be folded over. When folded over it's textured surface to textured surface. The "little triangle" is being folded over in this picture. |
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Fold this over on all six sides. |
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Fold this over on all six sides. |
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Fold over as shown. Make sure the "little triangle" on your left is trapped between the sides of the top. |
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Continue around the the hexagon, locking in the little triangle. |
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