It takes a while the first time, but I think I’ve got it down to about 15 mins plus glue drying time per box now. The advantage to this versus a straight cut with no label surgery is that it prevents the box and lid from bulging out in the centre of each edge. I don’t know why, but it works!
- decide on depth to remove.
- use x-acto/craft knife to cut down the box corners as far as the depth you wish to keep.
- Deeply score the inner surface along what will become the new edge of the box.
- Fold each of the four side ‘flaps’ that will soon be removed outwards 90 degrees.
- Lift the edges of the art/label/box cover on the inner surface of each flap with a craft knife.
- Run the knife along under the label for the length of the flap. It only needs to loosen the top few mm. It doesn’t matter if it leaves a good percentage of the cardboard layers attached in places.
- Carefully peel the label off the inner surface of the flap. This doesn’t have to be neat. When the peeling reaches the box/lid rim it will detach clearly, as little glue is used in this area. The part just peeled will later be cut off.
- Peel the outer label down to the fold line of the flap. This will come away easily now that you have a good piece to grip. This will later form the new inner part.
- Fold the grey cardboard that is now seperated back into the box 180 degrees from its present position. It will snap off. Don’t worry if the top of the box edge is now slightly ‘fluffy’.
- Stand the box on its side and trim the label along the white lines that used to be the inner surface of the lip/rim of the box (adjust trimming amount as required for different amounts of box removal). Use a metal ruler and craft knife.
- Trim triangles off each end of the label flaps to make a trapezium shape which you’ll fold into the box in a moment.
- Spread a thin coat of heavy/thick PVA or wood glue onto the label flaps that you’ve made. THIN! Fold flaps and clamp to avoid wrinkling, peeling, and warping. Bulldog clips would work. Paperclips might.
Some chopped games taking up less space on the shelf.
I promise my next post in here will be foam core based!