First stages of making

first layer.jpg
cover mould.jpg

Cover the mould with cling film to enable 

separation. As smooth as possible.

Use old (recycled) plastic tray to hold small amount of glue.  Put on first layer of paper.

Leave to dry for some hours before adding next layer. Length needs to include lid and box.

Paper needs to be torn into manageable strips. Tearing helps with smooth edges.

Remove from mould.jpg
More layers.jpg

Replace on the mould, use elastic bands to hold it in place.  Then add more layers of paper and glue. Keep it loose on the mould as you work, and a smooth surface.

Remove from the mould. Cut if necessary.

When firm enough to hold its shape remove from mould and slowly build up the layers to increase its strength.

Second Stage

stand alone.jpg
square the end.jpg

Cut the ends so they are square, use an object that has a right angle to check,

cut ends card.jpg

Cut thin card shape to cover each end.

Cereal package would be ideal.

cut ends.jpg
cut ends fastened.jpg

Fasten end in place using small strips of paper and pva.

Fasten other end to the box. Then continue to build up layers over the box until it becomes hard. Try to keep surface as smooth as possible.

Mark the cutting line for the lid, when the box is robust.

Mark the lid.jpg
Saws.jpg

When glue hard, cut lid from box. 

Use fine toothed saw or bread knife.

Liner 1.jpg
Liner 3.jpg

Cut thin card to act as a liner for the box.

Leave 1cm higher than box edge.

Use pegs, paper clips, pieces of sponge

or old rags to get pressure to the inside of the box both when fitting and gluing in place. 

Finished.jpg

When you are happy with the finished box it can be decorated with an appropriate finish.