For our school we had to make a flat pack product. After a whole proces I came to this idea, namely a flat pack bread box. You can see the whole process on http://bytebierjayflatpack.blogspot.be/ .
The flat pack bread box is made for using in a camper, a caravan/trailer or a boat. Obviously you can also use it at home. The nowadays bread box takes quite a lot of space. I wanted a strong reduction of these bread box, so it would be effective in use as in stow away.
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Step 1: Needs
- Bamboo plate / cutting board
- Organic Cotton cloth 1 meter by 1
- Additional wooden plate (no matter what) to make a template+ wooden boards
- 8 screws;
- Milling machine + milling head (diameter 24 millimeter)
- Saw machine
- Fine sandpaper
- Aluminum wire, length 3 m, diameter of the wire is 2 millimeter
- A screw driver
Step 2: Cutting Board
Cut your board so you have the correct measure (size 20 centimeter on 35).
That's the ideal measure for a bread box in a camper, a boat, a caravan...
Step 3: The Template
First of all you make a template, for example in wood, (the size has to be larger then 35 cm on 20), so you can mould easily and without errors.
Make a hole in the template (15 centimeter on 30) with the saw machine
Keep in mind that you have to take away 3 millimeter extra at the edges because of the cutter head.
Then you place on the template four extra boards with a screw driver
- length; 2 of 35 centimeter
- width; 2 of 20 centimeter
When you have done it right, the bamboo plate will fit perfectly.
Step 4: Milling the Bamboo Plate
You mill the plate with a milling machine.
Be certain that the depth is maximum 5 mm deep.
You have to pull the milling machine towards you.
Step 5: Sanding the Bamboo Plate
You can sand the plate a little bit with fine sandpaper so it looks more beautiful.
Step 6: Patterns of the Two Sides
Make the pattern of the bow in paper.
- width 20 centimeter
- higth 15 centimeter
Use these pattern of paper to mark the bow on the cotton cloth and cut it out.
Be certain that you leave a bit more space then the measure of the bow so you can sew it easily with the rectangular pattern.
Do this also for the other side.
Step 7: Pattern of the Rectangle
Draw a rectangle (35 centimeter on 43) on the cotton cloth.
Make also certain that you leave a bit more space so you can better sew the bows on the rectangle.
Cut it out now.
Make also four small pouches in the canvas size (2cm on 3). So the arch structure will better stay on his place when you put in in the cotton shell.
Step 8: The Sewing Stabbing
Learn the blanket stitch on a piece of cloth. You will need it for sewing the bows on the canvas.
Learn also the lockstitch with space. You will need it for the finishing touch of the rectangle cloth.
Step 9: The Shell
First I suggest you to make a little protoype.
You sew a bow on a little rectangle. Use the corrrect stitches.
Make also a skeleton in solid wire so you can see if your prototype is allright.
Now you are ready for the big job.
Sew the bows on the rectangle with the blanket stitch.
Work out the rectangle with the lockstitch
Then you can sew the four little cases in the shell.
Step 10: Framework Mold
Take the bow in paper and draw it on a wooden plate.
Saw it out with a sawing machine.
Now you have a mold out of wood so it will be easier to make the arch structure.
Step 11: The Skeleton
With the mould you can easily bend the aluminum wire 5 times.
Step 12: How to Use It
Put the skeleton, made of aluminium, into the cases of the shell, so it will be firmer.
Now de structure is standing.
Take the bamboo plate and lay your bread on the plate. Then you can close it with the shelter.
Now you have a lovely bread box. Easy to flat pack. Ready to use.
You can use the backside of the bamboo plate as cutting board for your bread.