First stages of making
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.
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.
Cut the ends so they are square, use an object that has a right angle to check,
Cut thin card shape to cover each end.
Cereal package would be ideal.
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.
When glue hard, cut lid from box.
Use fine toothed saw or bread knife.
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.
When you are happy with the finished box it can be decorated with an appropriate finish.