Introduction: Plywood Jack-O’-Lantern Tea Light Bags (8 Faces Included)

By AwesomeWoodThings.com
About: It’s not just things made out of wood… it’s things made out of wood that are awesome! My name: Matt Haas

It is a fun Halloween tea light jack-o'-lantern bag... but, it's not made out of flimsy paper. Rather, it's made out of plywood so it will last for years either indoors or out in the elements! Eight spooky faces are included... make your favorite, make all eight, or make any number in between!

The sides of the "bag" can be straight (recommended) or bent so they more closely mimic a real foldable paper bag.

You can use traditional woodworking tools or computer-controlled machines: CNC Router or CNC Laser engraver machines.

Supplies

MATERIALS

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TOOLS

  • CNC Machine and/or Laser Engraver (optional)
  • You'll need to know how to use these machines because providing exact instructions for every possible software/hardware combination would be nearly impossible.
  • Drill or Drill Press and a drill bit or Forstner bit.
  • Table Saw
  • Scroll Saw or Bandsaw
  • Disc Sander
  • GRR-RIPPER Table Saw Pushblock (model: GR-100 3D) - Amazon: https://amzn.to/3PnNHxv

Step 1: Download the Cut Files

This download contains AI, PDF, SVG, and DXF versions of everything you'll need to make this project with traditional woodworking tools (scroll saw and table saw) or a CNC router/laser engraver. Even low-end laser engravers will work because the wood is so thin!

FREE DOWNLOAD: https://payhip.com/b/muhf9

Step 2: Cut the Face/Back Panels (Scroll Saw or CNC)

Choose one of the methods to cut the face shapes and project parts:

Traditional tool (scroll saw) method:

Use traditional tools, such as a table saw, to cut a sheet of plywood to the final size of the front/face panel: 7" x 11".

Print one of the PDF files containing one of the 8 jack-o'-lantern faces to paper and apply spray adhesive to the back.

Stick the jack-o'-lantern printed document on your 7" x 11" panel.

Cut out the face shapes using your scroll saw. Use a band saw to cut the zig-zag shape. The zig-zag mimics the rough-cut top of a real paper bag. I think this adds a nice stylized touch.

Do the same for the empty (no face) back panel.

CNC Router or CNC Laser Engraver method:

You will need to know how to use your machine to import the provided art files (DXF or SVG) and get your machine to carve/laser-cut the face shapes and the outline of the bag with its zig-zag top. The zig-zag mimics the rough-cut top of a real paper bag. I think this adds a nice stylized touch.

==== Small laser engravers only ====

The laser engraver used in the video can cut a maximum of 8" x 8" so a workaround was needed to cut the larger shape of the bag itself, which is 7" x 11", using traditional woodworking tools.

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Note: The final size of the front/back panel will be 7" x 11".

Don't forget to cut an empty (no face) back panel too.

Step 3: Cut the Side Penals

Choose one of the two side panel options below.

It is strongly suggested you choose the Flat-Side method because the final product will look just as good and will be equally endearing/fun compared to the difficult Bent-Side method. Again, the Flat-Side method it's much, much easier to make! Trust me... you want to choose the Flat-Side method!

The Bend-Side method is for experienced woodworkers only.

Flat Side (rectangle box) (Easy. Recommended)

Use a CNC machine or traditional woodworking tool to cut a rectangle 3 3/4" x 11" (3.75" x 11"). If you're using a traditional woodworking tool, a table saw is recommended because it can precisely cut a straight line. You can use other traditional woodworking tools, such as a band saw or scroll saw if you cut or sand the plywood to a perfect rectangle using a disc sander, belt sander, or another sanding method.

You will need 2 side panels for each tea light bag. (16 side panels if you make all 8 tea light bags)

Bent Side (looks more like a real paper bag) (Very Hard. NOT RECOMMENDED!)

Bent Side CNC Method:

  • Use a CNC Router or CNC Laser engraver to cut the side pieces out of plywood.

Bent Side Traditional Tool Method:

  • Use a traditional woodworking tool (table saw is recommended) to cut the side pieces out of plywood to 1 7/8" x 12" (1.875" x 12")
  • Add the spike at the bottom. It's a 37-degree angle. The distance from the top to the long-part of the pointy spike should be 10 7/8" (10.875")

Rip the long side using a table saw with its blade at 12-degrees (102-degree) angle.

Cut two triangles following the size shown on the template. The sides of the triangle do not need to be cut on an angle.

You will need 4 side panels and two triangles per tea light bag. (32 side panels and 16 triangles if you make all 8 tea light bags)

Step 4: Cut the Base

Use a traditional woodworking tool (table saw, band saw, scroll saw, or jig saw) to cut the base out of a solid pine board. Any type of wood will suffice. Note: Pine boards are the lowest-cost wood you can buy. Yay! Fun fact: Nobody will really see this piece of wood because it will be at the bottom and inside the "bag" hidden from view.

Straight Wall Method (Easy & Recommended) - Choose this method!

Simply cut a rectangle with the blade at the default 90-degree angle to this size: 6 3/4" x 3 3/4" (6.75" x 3.75")

Optional: Use a drill press to cut "weep holes" in the base to allow rainwater to exit the bag rather than pool on the bottom.

Straight Wall Method (Hard & Not Recommended) - Do NOT choose this method!

Rip-cut the board with the blade at the default, straight-up, 90-degree angle to 3 3/4" (3.75") wide. The length can be any size because you will bring it to size in the next operation.

Cross-cut the board with the blade at a 12-degree (102-degree) angle to 3.75"

IMPORTANT: Using a table saw with the blade at an angle requires extra safety considerations and should be done by an experienced woodworker. Use a miter gauge to cross-cut this operation rather than a rip-cut with a fence.

Optional: Use a drill press to cut "weep holes" in the base to allow rainwater to exit the bag rather than pool on the bottom.

Step 5: Paint!

Use a paint roller to apply paint everywhere... all sides. It's best to let one side dry before painting the opposite side.

Step 6: Assemble

Wear disposable gloves to apply super glue to all sides that join.

Trust me, super glue on your skin is not a fun experience!

Use the activator spray to make your life easier by instantly bonding the glue after you have the pieces joined together perfectly. Do this in a well-ventilated area and use breathing protection because the stuff smells, and is, nasty!

Step 7: Drop in a Tea Light and You're Done! Yay!

Turn on a tea light and drop it in the bottom of the bag. Boom! You're ready to scare your friends with this spooky decoration.

You'll be able to enjoy your Halloween tea light bag while resting assured it will last for many years because it's made with sturdy wood rather than flimsy paper!

Watch this build process on YouTube:https://youtu.be/GLMgdt335KY

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