Instructables
I have always wanted a Cardboard Deer Head like the ones you see at trendy shops or at http://www.cardboardsafari.com/shop/product_cbs1002.php but couldn't justify spending money on something I know I can make myself.

In this Instructable I will show you how I made my Cardboard Deer Head. Its not perfect but I am happy with it. The total project took me about 10+ hours off and on. My best advice is too take breaks and don't get frustrated (cutting gets a little tedious).  If you had a laser cutter this would probably take you less than 30 minutes of actual work.

PLEASE NOTE
Cutting cardboard can be difficult. Please be careful to not cut yourself, always cut away from yourself!

Shall we get started?
 
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Step 1: Supplies and Materials

The Best part about this Instructable? ITS FREE! That"s right free, that is of course if you have most of the supplies on hand.

Supplies
Scissors
Box Cutter
Hot glue gun
Tape (masking tape works well)

Optional (but recommended)
Exacto-knife

Materials
Cardboard (best if it is clean, not bent up, and doesn't have anything printed on it)
Template printed off (I attached a .zip file with the template scaled so you can print at any standard printer. Also a much larger .png file if you want to scale up or play with)
Pop top

Step 2: Cut out the template

Start by cutting out the template. (I provided a .zip file on the last step)

Once you cut out all the pieces tape together any pieces that weren't able to be printed on one page. ( The head with the antlers and the middle) Look at the closer images for reference. If you have any questions feel free to ask

After you have taped the pieces together that needed to be, loop your masking tape on the back of the template pieces.
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kaitlyn.c.becker made it!3 days ago

I had a ton of boxes lying around and didn't want to just toss them out. 6 hours of cutting and a bunch of sore fingers later, I have an awesome-looking piece of decor for the living room. Thank you for this wonderful how-to and template! We're going to really enjoy our new buddy. :)

IMG_4698.JPG
steinauf made it!3 days ago

Using the dxf file provided by other users (thanks!), I made this from CB flute doublewall corrugated board. Board thickness is 5/16". Cut using a robotic cutting table. It's a little wobbly at the base, but I'm going to see if hot gluing some of the joints will improve that.

deer head.jpg
noelle.kruppa made it!10 days ago

Hi! I made a mini at work with glitter nail polish, a highlighter, sharpie and a granola box... sometimes you have to make due with your resources. Anyways, it is adorable! Thank you for the plans! This will be like a practice before the big one :)

IMG_3822.JPGIMG_3826.JPGIMG_3828.JPG
Soupraok (author)  noelle.kruppa8 days ago

Looks great! Nice job using what you have!

RicardoN19 days ago

hi can somebody send more templates from more animals like a RHINO.

maznieto@gmail.com

Thanks!

can someone send me the corrected format? plis camilamunozespinoza@gmail.com

James-B2 months ago

Here's how the shield and the fittings to lock the neck to the shield turned out.

2014_11_07_0939.JPG
James-B James-B24 days ago

Here's how it fits onto a 4 foot x 2 foot piece of 3mm ply.

There are two cut lines across the ply that indicate where it separates into three pieces, so that each piece will fit into the 24" x 18" working area of my ULS VLS4.60 LASER.

The shield is in 3 layers that are glued together. I used 5 minute epoxy. They have to be assembled in the right order for the fittings on the spine and the two parallel outrigger pieces to mate with the shield.

If you look at the attached image, you'll see how the pieces lock together

If anybody wants it, I have the file for an assembly jig that holds the 3 shield pieces in the correct positions while the glue sets.

The main spine is in two layers that are glued together back to back. I made one deer head using 5 minute epoxy glue to join the two halves of the spine, and one using Duck brand Permanent Double Stick Tape. Both worked successfully, but you'll need a lot of small clamps or clothespins to hold the pieces together while the epoxy sets.

While I sized it for 3mm ply, the ply that I have been getting lately from my local Home Depot is actually 2.75 mm thick, so the sections from the ears forward were sized for 2.75 mm and 5.5mm slots to reduce the tendency of the parts to wobble.

My experience is that the antler section is very prone to breakage, so I arranged the pieces so that a spare could be cut out of what would otherwise be wasted material.

CorelDRAW X5 file (500KB)

DXF file (6MB)

.You may have to separate the 3 pieces in your graphics software, but when separated, the pieces should fit into most platform style LASER cutters.

deer 3mm ply.gif
James-B James-B23 days ago

For those interested, here's the DXF file for the jig to hold the 3 pieces of the shield in the correct alignment for gluing. It is sized for 3 mm ply that I used for the deer head pieces, but it is quite loose with the 2.75mm ply I have been getting.The attached photograph shows how it slots together.

The front section of the shield goes into the assembler first (good ply side down) and with the top of the shield at the (as shown) right end of the assembler. The glue is applied, and the middle section gets placed on top, and then more glue and the back section is fitted. Clamps, clothes pins, or fold back clips placed around the edge of the shield hold the three pieces together while the epoxy cures.

deer_shield_assembly_jig.jpg

James B...maybe I am not seeing it but is the pattern for the locking neck to the shield in the pattern - can you send it to me? That idea is so great!!!!

This side profile of the neck section of the spine piece and the corresponding slice through the three glued layers that make up the shield, should make the detail of the locking shapes just a little easier to understand.

deer_3mm_ply_neck2shield.gif

Can you please send be the DXF file at fermatrix@outlook.com . Thanks!

a copy of your plans would be a great addition and save me a lot of work if possible. kind regards. sandra.bryant@stft.nhs.uk

Claptrap6 months ago

Redrawn and scaled for 3 mm plywood. Worked out great.

DXF file available if anyone wants it.

DSCF1632.JPG

Can you please send be the DXF file at fermatrix@outlook.com . Thanks!

Can you please send be the DXF file
jamesoliverbrookes@gmail.com
Hi! Want your DXF file please! Thanks !! bbchatton@gmail.com

hi could you please send me the dxf drawing.Thanks

travismurphy@y7mail.com

Hi I would love a copy of your file. I have made the original but did not think to redraw for 3mm ply. greatly appreciative. sandra.bryant@stft.nhs.uk

hi could you please send me the dxf drawing.

lukerubery@icloud.com

thanks alot

hi, could you send me the dxf file please. it's for a christmas gift. my brother would love that ;)

sfried16 (at) gmail.com

thanx a lot! and merry christmas ;)

Hi

Are you able to send me the updated file?

jt.dalen@gmail.com

Thank you :)

Hi I really want one, could you mind sent the file to email: fj3166@gmail.com

Many thanks!

could you send it to me too? thanks a lot :) tiziana.fischer@hotmail.com

Hi, i really want to know if you can send this to my email please. cloe.rtpo@gmail.com

Claptrap would love your dxf please.
Ben.patt.nz (at) gmail.com thanks

it would be great, if you could send me your dxf file

isi.ja(at)web.de

thanks a lot

geryl Claptrap3 months ago

would it be possible for you to send me the dxf file

email: lefebvre_ge@student.kings.edu.au

thanks

@claptrap That is amazing! I would love the file if you dont mind. Please and thank you!!

I will be grateful for file.

clashmind@mail.ru

clashmind@gmail.com

For any one who wants it..... files available at
www.fusion32.com.au/dxf_files

Hi! Could you send me the DXF file please? My email is: alucietto@yahoo.com.br

Thanks!

Hola me podrias pasar el escalado quedaría muy agradecido

??????

Woaw!! Can you send me the files to nicolasncb@hotmail.com ? Thanks;)

Print these 3 pdf's with a lasercutter on 300 x 600 mm sheets of 3 mm MDF. Paint it white and assemble. Cheers

2014-08-11 19.16.14.jpg
Can you send me the files please.
Jamesoliverbrookes@gmail.com

¿This PDF and autocad files correspond to that pict? ¡Thanks a lot!

BettyM11 month ago

hi could you please send me the dxf drawing.

mothernaturesaromatherapy@gmail.com

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