Halloween is here, and after picking up a Disney villains coloring book and being inspired by the white-on-black variant from a standard coloring book, I wanted to recreate the look and come up with some truly evil Halloween decor.
Each villain was made using a different method: 3d printing, scroll saw cutting, and coping saw cutting.
Here's how I put them together:
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Step 1: Supplies
The materials I used:
12x12 3/8" plywood board
10x13 3/8" plywood board
1/4" cedar, cut to 3/4" strips
1/4" purple heart
The tools I used:
Step 2: Scan Your Villains
I started by choosing 3 of the villains from the coloring book and then scanned them into my computer. I took the scans and brought each of them into Inkscape. Using the 'trace bitmap' effect, I created a vector of each scan, and then used the selection tool to clean up the vectors and remove any of the extra elements that I didn't need.
Step 3: Create a Template
For the 2 villains that were being cut, I printed out the vector picture and taped both halves together. Using spray adhesive, I glued the printouts to some transfer paper, and then cut each character out.
Step 4: Creating a Frame
For Jafar and Maleficent, I took the 10x13 boards and painted each black. For the Evil Queen I did the same on a 12x12 board.
I took the cedar strips and started making the trim to fit the outside of each board. I used a sander to make the 45 degree angles for each corner, but this could easily be done with a miter saw or band saw. After each piece was cut out, I glued up the strips and used a brad nailer to nail each of the strips to the boards.
I repeated this step for each of the boards.
Step 5: Cutting Maleficent
For Maleficent, I decided to scroll saw cut her outline out. I took the template I made earlier and stuck it to the 1/4" plywood board. I took the board to the scroll saw and cut out the outline.
I took the board to the drill press, and drilled starter holes for every section where I needed to feed the scroll saw blade through to cut the section out. I then cut out the rest of the character.
I removed the template, and then spray-painted the pieces white. After it was all dry, I used wood glue and glued the pieces to the frames.
Step 6: Cutting Jafar
For Jafar, I decided to hand cut his outline out. I took the template and stuck it to the 1/4" board, then used a coping saw to cut out the outline of the character. Like Maleficent, I drilled starter holes in each section for the coping saw blade, then cut out each piece with the coping saw.
It took a long, long time.
I spray-painted the outline white, then glued it to the frame.
Step 7: Printing the Evil Queen
For the Evil Queen I decided to 3d print her outline. I took the vector I created in Inkscape into Fusion 360 and extruded the outline up 1/4". I exported it to Cura (or your 3d printer software of choice), inverted the outline, and then sent it to the 3d printer.
Once it was done printing I took it off the print bed, and before taking it off the raft I super-glued it to the frame (hence why I inverted it in Cura before printing it). Once the glue set, I removed the raft from the print. Doing this also ensured that the smaller pieces would be in the same place they printed.
Step 8: Add a Pop of Color
I wanted to add a small piece of color to each, reflecting the inspiration I got from the coloring book.
For the Evil Queen I printed a red apple.
For Jafar I cut a small piece of bloodwood for his jewel.
For Maleficent I used purpleheart for her eyeshadow.
After cutting (or printing) each piece, I glued them into place on each of the frames.
Step 9: Sand and Oil
I took some sandpaper and smoothed out the cedar, then took some Danish Oil and oiled the cedar pieces, as well as the bloodwood and purpleheart.
Step 10: Hang, Enjoy
The last thing to do was to hang my new evil creations, and stand back and admire my creations while laughing maniacally to myself.
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Participated in the
Halloween Contest 2019