Medicae Outpost Part I

As promised, I will spend the next few posts on the Medicae Outpost I built a while back. At the time, I kind of built it on the fly. So, I'm building another, this time with the goal of finishing with a reproducible process and template. As you read through this post, you can click on most the images to view a larger version. We'll start with the supplies. The list is:

1. T-Square for good right angle cuts
2. Metal ruler
3. X-acto knife with new/sharp blade (for cuts that don't go through the material)
4. Box cutter with new/sharp blade (for cuts that go all the way through the material)
5. Pencil
6. Clear tape
7. Wood glue (I prefer this to craft glue, but either will work)
8. 5mm foamcore board (you'll need a sheet that is at least 12"x12"). Foamcore consists basically of two sheets of paper on top of and underneath a layer of dense foam-like material.
9. Thin cardboard (such as a cracker box)

The first items to cut out are the sides of the building. With the foamcore, cut out two 2"x12" strips. On each piece, draw a vertical line every two inches. It is important that these lines be square. Next, starting on the left of both pieces, draw a line 5mm to the left of the 1st, 3rd, and 4th vertical lines. You also need to draw another vertical line 5mm from the right end of each strip. The 5mm is important because it is the thickness of the foamcore. The last line to draw is one 5mm from the top of each strip running the length of the foamcore.

Once both strips are marked up, cut along all the lines down to the paper on the backside. You will be cutting through the top piece of paper and through the foam. Do not cut all the way through the paper on the bottom. In all the places where a 5mm strip exists, pull the paper off the top side and scrape out all the foam in the cut area. Make sure you have the area clear of all the foam and that the bottom side paper doesn't get damaged.

With everything cut and scraped on both strips, it's time to fold the sides. Using the photo below as a guide, you need to make sure each fold results in a 2" side on the outside measurement. Single cuts fold outward and 5mm cuts fold inward on top of themselves. To put a temporary hold on the folds, I've used clear tape. You don't have to do this, but it comes in handy when it's time to glue down the top.

I'm not gluing the sides together. I'll use the top to hold them permanently in place. This way I'm assured the sides will conform to the shape of the top. Cut out the top next. It is a cross whose sides are all 2". I cut this out of foamcore as well. As with everything else, make sure the cuts are square.

Cross/top is cut out and sides have been folded - time to put it together. Run a line of glue across the top of one of your 12" side pieces. The glue should go in the 5mm strip that runs the length of the side. Set the top in place on the side piece. While pulling the sections of the side tight around the cross, place tape around the edge to hold the pieces together while the glue dries.

That'll do it for tonight. We'll let the glue dry and continue with the other side section, the slanted roof sections, and the building details on the next post...