Hat Holder

The first step in this project is to build the box to hold the hat.  I used a free site called boxes.py to set this up.  I generated the abox template.

The abox template is designed with a bottom and finger joints to support the bottom.  I am removing this from the design since we want the hat bill to slide down into the box. It is perfectly fine for it to hang out of the bottom of the box.

To accomplish this task, I have used the XCS feature to hide layers to expose only the through dados that are part of the design to hold the bottom.  Just select all and delete.

I then used the layers feature to show the rest of the design again. I also deleted the bottom of the box as we don't need this part.

Since we are going to hang this on the wall and maybe add hooks for keys, we need to extend the back of the design.  To do this, simply add a rectangle that exactly the same width as the back, including the finger joints.  

I then used the alignment tool of XCS to make sure the two parts are perfectly aligned horizontally.  I then moved the rectangle up with the arrow keys to ensure it does not move left or right.  I moved it until the two vectors overlapped.  Then use the combine tool to unite the two parts. 

Next, we need to shape the front of the hat holder.  I decided to use a circle and elongate the circle to create a gradual curve.  I then overlapped it with the front piece.  Then I used he combine tool to subtract the overlapping area.

Next, I always like to do a dry fit to make sure all the parts fit together correctly and this helps me lay out the parts for glue up.  If parts fit too tightly you may need to sand the edges of the box joints.