Coffin Razor Box

Toe Pincher Coffin Box
There has been interest in the razor box patterns previously posted and an occasional requests for the older style coffin shaped boxes. (Previously, I had posted a tutorial for making rectangular coffin boxes on SRP’s forum.) I’ve put in a fair amount of design time, with multiple prototypes and drawing revisions, and I’m now comfortable with making these patterns and a tutorial available.


These are not replicas of the old boxes, but a scored and folded pattern that mimics the shape and look. During my research into how the original boxes were made, I found this old SRP thread, Razor coffin to box question, post #5 which summarizes one possible method of manufacture and suggests a reason for the tapered shape on the old coffins. I also found this from Neil Miller,Coffin Box Deconstructed.


For these boxes, paper with a linear pattern or grain direction will not work well for the tapered bottom section. Solid color, irregular pattern or finely textured paper will work best.

Making the Coffin:


Lay the razor you’re making the box for within the dotted lines of the pattern and determine if it will sit all the way to the bottom. If not, make a mark at the lowest point of the razor. Next, with the razor in place determine the length from the bottom score and the tip of the razor’s tail. If this length exceeds 6 5/8 inches, the cap can be lengthened relatively easy.


To adjust the length of the cap, cut the pattern in two and tape one half to another piece of paper. Position the other half using a straight edge, line up the outside edges of the pattern with the desired increase between the 2 halves. Make sure everything is square and straight, tape in place. It can then be cut and scored. To shorten the cap, follow the same procedure but overlap the cut pattern halves by the desired amount.

The general directions for the single or double are similar, with the inserts being the biggest difference. The photos are from making the double.


The first step is to cut the carton pattern away from the other pieces and cut several triangles, as in the photo, with the knife, this allows you to tape the pattern down in several places in the middle, instead of outside edges only.


Position the pattern on the paper and tape it down over the triangles. Here, I’ve used paper medical tape (I’ve found that cellophane tape will often pull up paper fibers when being removed) but a painters tape should work just as well.
Attachment 189328


Cut out the perimeter using a straight edge and knife, be very careful not to overcut into other parts of the carton. Separate from the rest of the paper, in some of the tighter areas you may need to carefully use your knife to make any additional cuts. Do not remove the pattern yet.
Attachment 189329Attachment 189332


Next up is to impress the score or fold lines. A variety of tools could be used to do this, what I’m using is part of a binder clip mounted in an Exacto handle. Whatever you use it needs to be capable of handling a lot of pressure and be able to move smoothly over the score lines.


Use the straight edge to guide the tool and use a lot of pressure to give it a good impression. Die cutting machines that cut and score in one hit use well over 60 tons of pressure, obviously we can’t do that, but a clean line with some compression of the paper will work. Use the straight edge as you begin folding to keep everything straight and crisp. Pay particular attention to the score lines on the tapered bottom piece. The score on each end flap is at a slightly different angle than the one next to it. Crisp, precise, scores and folds will give the best results. Most of the score lines will also benefit from being folded over and rubbed with a smooth surface to flatten them.
Attachment 189330


Single coffin:


Begin gluing with the insert. Glue, fold over the long flaps and rub to insure good adhesion. Apply glue to the side tab and fold, inserting the tab under the flap. Here I use craft sticks and binder clips to clamp.


The bottom portion is glued in the same manner, leaving the flaps on the bottom unglued. Clamp the seam line and make sure it is lined up the full length and has good adhesion. The cap has a double fold on 2 faces; make sure that lies as flat as possible after gluing. Fold the cap end flaps and glue following the sequence on the pattern.
On the single coffin, fold the bottom flaps last, after gluing the insert in. Make sure that it sits deep enough that no open corners are visible where the insert and shoulder meet. It will also be easier to ensure full length adhesion of the insert to the inside of the bottom piece. Trim any of the insert that extends past the score line of the bottom flaps and glue the bottom flaps.
Attachment 189331


Double coffin:


Cut both of the insert pieces, then score and fold. The folds of each will be mirrored, one left and one right, if your paper is not the same texture or color on both sides be sure to cut both pieces with the pattern’s printed side up. Glue the sections without top flaps (A) to each other, outside to outside, leaving the area below the score at the bottom unglued. Fold the rectangular piece (B) in half and glue to cover these sections. Glue and complete the rest of the insert.


When inserting into the bottom, glue the rectangular and tapered outside flaps in place, trim if needed. The unglued lower section of the doubled center is opened to make a T that should be flush with the bottom, trim the outside of the T if needed. The first bottom flap is glued to this T and the rest of the bottom flaps are then glued in sequence. This will secure the center divider in place.
Attachment 189333Attachment 189337


The angles add complexity and would take quite a bit of time for me to modify the drawings, so I’m offering a single coffin pattern in 2 sizes and the double razor box pattern in one size only. It is a large size and should work for most razors.
If you have a CAD program, I will e-mail a .dxf, if requested, so you can modify another size to this style box.


If you would like to try your hand at embossing a pattern, it can be done the same way the scores are made.


I cannot guarantee fit or suitability for any given razor. These coffins are only as sturdy as the paper used to make them, original razor coffins were made of much thicker pasteboard.


Please, post pics of your completed coffins, we’d all love to see them.

Great project:) very well done.

This is really excellent. I am going to try this.

Thank you. Saved for future reference.

Added to my reference file...thank you!
~Richard

Me too! thank you.
MIke

Excellent work Sir
Have some cutting and folding to try out now thank you

That's pretty neat.