Marginal Material Case Instructions

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These are the tools needed to construct an mm case: (from left to right) scrap paper, PVA, T-square, ruler, dividers, glue brush, cheesecloth, scissors, bone folder, pencil.

Grain direction of board must be determined by bending board the long way and the short way. The grain runs in the direction of least resistance, the way that pushes back the least when folded.

Mark the grain direction on board with pencil. The arrow should be parallel to the direction that is easiest to fold, in this case, the long way on the board.

Use a ruler to measure the height of book. Make sure to line up ruler exactly at the bottom of the book. Write down measurement.

Use dividers to measure thickness of book. Measure the book at several places around the edge to determine the thickest part. The thickest part is the measurement you will use.

Mark height of book on board. The grain direction runs parallel to the direction of the height.

Using the board shear, cut a strip of board that is the height of the book. This is called the horizontal strip.

Bend the strip back on itself to make sure the ends match in width. If they do not match, then cut another strip.

Begin to mark strip for scoring and folding. The first mark is 2 mm smaller than the thickness of the spine.

Next mark the width of the book using the ruler. Then mark the exact thickness of the spine using the dividers.

Next mark the width of the book using a ruler. Then make a mark 2 mm bigger than the thickness of the spine.

Make a mark for the flap that is 5 cm wide. Then cut off the extra board from the strip.

Line up the strip on the edge of the table. Make sure the edge of the board is flush with the edge of the table and the T-square.

The horizontal strip should look like this.

Place T-square 1 mm to the left of the first mark to allow for the thickness of the bone folder.

Hold the T-square firmly and score the board with the point of the bone folder several times.

Lift up the board with the bone folder and push the board into the edge of the T-square to fold it into a right angle.

Using the T-square and the bone folder, score all of the marks on the strip.

Use the bone folder to make crisp folds at the creases.

Put the book in place and check for a proper fit. If the book does not fit, begin again.

Use scissors to cut a triangle of board from both sides of the flap.

Prepare to cut second strip. This is called the vertical strip. The folds will run parallel to the grain direction of the board. Use the book width on the horizontal strip to determine the width of the vertical strip. This is more accurate than using a ruler.

Make this mark right at the crease.

Cut the board using the board shear. Bend the strip back on itself to make sure the ends match in width. If they do not match, then cut another strip.

Center the horizontal strip on the new strip. Mark at both top and bottom ends.

Using dividers, mark the thickness of the spine of the book to the outside of the height mark.

Using dividers, mark the thickness of the spine of the book to the outside of the other height mark.

The vertical strip should look like this.

Line up the strip on the edge of the table.  Make sure the edge of the board is flush with the edge of the table and the T-square. 

Place T-square 1 mm to the left of the first mark to allow for the thickness of the bone folder.

Hold the T-square firmly and score the board with the point of the bone folder several times. 

Lift up the board with the bone folder and push the board into the edge of the T-square to fold it into a right angle.

Using the T-square and the bone folder, score all of the marks on the strip.

Use the bone folder to make crisp folds at the creases.

Put the first strip in place and check for a proper fit. If the strip does not fit, begin again. Mark the flaps on the new strip about one quarter of the distance from their ends.

Using the board shear, remove ends from flaps.

 

Put first horizontal strip in place on top of second vertical strip. Put book in place.

Fold vertical flaps in place. Tuck angled tab of horizontal strip in place. Check for an accurate fit. If case does not fit well, make horizontal strip again.

Mark the midpoint of the center section of the vertical flap.

Make marks 3 cm to either side of the center mark.

Make a mark 2 cm in at the center mark.

Connect the marks on the edge to the center mark to form a triangle.

It should look like this.

Use scissors to remove triangle from board.

Put beveled flap in place on top of edge where triangle was removed. Trace around it.

Prepare to glue by positioning vertical flap on scrap paper. Add strips of scrap paper at edges of central panel to be glued. Swirl excess water from glue brush.

Glue central panel, taking care not to glue traced area around removed triangle.

Put horizontal flap in place on glued central panel.

The blue panel of the horizontal strip should be put down on the glued area.

Press horizontal flap in place with hands or bone folder. Put under a pressing board and weight to dry.

Make a paper title label for the mm case. Trim it to the thickness of the spine of the mm case with a scalpel and ruler.

Glue title label with PVA. Use scrap paper with no printing to keep label clean.

Put title label in place on spine of mm case. Rub with a bone folder through clean scrap paper.

Return completed case to stacks.