Intro: Die Hard Christmas Ornament
This is my version of the popular Die Hard Christmas Ornament that can be found elsewhere on the internet.
( I'd appreciate your vote for the Metalworking Contest ) :)
"Come out to the coast, we'll get together, have a few laughs..."
Step 1: Step 1 - Print Pictures
Print 3 copies of the supplied picture, (on one sheet of good quality paper), and cut them as shown.
Picture size: 7.1 cm x 16.5 cm (2.79" x 6.49")
Image can also be found here:
Also, easy to print Word document with the three pictures ready to download. (Courtesy of "hoozdman")
Step 2: Step 2 - Cut Out Head & Hand
Take the first of the three pictures and very carefully cut out the head and the hand holding the lighter and discard the rest. Then, using a black marker, very lightly touch up the white edges around the head and hand for a nicer look. But be careful it doesn't bleed into the image. Perform a test with the picture scraps first. If your marker is too new it may bleed into the image no matter how gently you do it. If that's the case, try using a semi-dull marker.
Next, cut 9 very small, (about 1/4"), squares, of double sided foam mounting tape. Then, stack them three layers deep so that you end up with 3 sets.
Next, stick 2 sets on the back of the head you cut out earlier and the remaining set on the back of the hand.
Finally, stick the head exactly on the head of the second picture, then do the same with the hand cut-out but paste it slightly to the left of hand on the picture. It looks a bit "off" but it will look better when the picture is installed inside the box because of the curvature... (I failed to do that when I put mine together)
After this step it should have somewhat of a 3D look.
Set this picture aside until final build.
Step 3: Step 3 - Make Template
Take some thick paper and cut a 36.5 cm x 8 cm rectangle. (approximately 14.25" x 3.5")
Draw lines at the following measurements:
7.1 cm (2.79") from the edge
10.6 cm (4.17") from the 1st line
7.1 cm (2.79") from the 2nd line
10.6 (4.17") cm from the 3rd line
1 cm (0.39") from the 4th line
Next, make bends at each line and close cube with a piece of tape. Use the third photo to test the fit.
Step 4: Step 4 - Cut Sheet Metal
Using the paper template, cut an exact copy out of thin sheet metal. (I used aluminum)
Next, carefully score the lines on the cut piece with a sharp metal object or a diamond tipped pen.
Step 5: Step 5 - Make Bends
Using a sharp edge of a table or piece of wood with a sharp edge, bend the metal as far as possible and complete each bend by hand by bending a bit further than 90° then back to 90° for better results.
For the smallest bend, place another board on top. (see photos)
Step 6: Step 6 - Close the Rectangle
Using regular double sided tape, (no foam), close the metal rectangle shut.
Next, use the 3rd picture to test fit and make adjustments as necessary.
Step 7: Step 7 - Sand & Clean
Using sandpaper, sand off any sharp edges, then clean entire cube with a moist cloth.
Step 8: Step 8 - Install Picture
Apply regular double sided tape to edges of picture, that you set aside previously, and paste inside rear of cube as shown.
Step 9: Step 9 - Install Black Foamy
If you don't want light to shine through the top and bottom of the picture, you can cut some foamy strips, pre-curve them and stick them with regular double sided tape at the back to block the light. (as shown)
Step 10: Step 10 - Install Hanger
If desired, you may glue on a hook or tie a ribbon to the cube to hang on your tree or leave as is to display on a shelf or mantle. You can also add rubber feet at the bottom. (see photos)
Step 11: Step 11 - Adding Special Effects
Buy one of those cheap LED candles and trim the tip.
Next, add a piece of double sided foam tape to the back as shown, and stick the LED candle tip to the back of McLane's lighter flame.
Turn on the candle & enjoy! :D
(Again, I'd appreciate your vote below)
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