I don’t often say outright that I’m proud of myself, but I have to admit I was really proud of this project. I searched everywhere for letter-shaped boxes and came up empty, so I decided to make them myself. I had almost no confidence it would work — but it did, on the first try. That rarely happens, so I ran with it and created a set of handmade letter boxes perfect for party favors and unique gifts. The process is straightforward but benefits from careful measuring and patience. Grab a ruler and follow the step-by-step instructions below to make your own.
Handmade letter boxes make excellent keepsakes. Give them away and enjoy the surprised reactions when you reveal, “Yeah, I made that.”
You’ll need:
- Cardboard (I used thin corrugated cardboard)
- Pen
- Ruler
- Large letter printouts — use a bold, block font and print at the size you want for the finished box
- X-Acto knife or box cutter
- Hot glue gun
- Craft paint (white primer recommended)
- Paint brushes
Step 1 — Cut the base letters: Trace the printed letters onto your cardboard and cut them out. These cutouts will form the bottom of each box. To create the lid, trace the letter a second time and mark a 1/8″ outline around the outside. Connect those marks with your ruler to create a lid that is 1/8″ larger than the base. If you’re using very thick corrugated cardboard, increase that allowance slightly so the lid fits over the bottom.
Step 2 — Cut side strips: Cut several long cardboard strips to form the sides of the boxes and lids. The strips for the lid should be 1/2″ narrower than the strips for the base so the lid can slip over the bottom. Longer strips reduce seams, so use the longest pieces that fit your letter shape.
Letters without interior holes are the easiest to build. If you want a true A or O with a hole in the center, follow the same steps but cut an extra strip for the interior hole area on both the base and the lid.
Step 3 — Assemble the base: Heat your hot glue gun. Begin attaching the wider strips to the base letter. Apply a thin line of glue along the corrugated edge and press the strip onto the edge of the letter. Work around the shape, bending and creasing the cardboard at angles to follow the letter outline. Start each new strip at a corner or intersection to minimize visible seams, and glue seams together with a thin bead of glue along the corrugated edge.
Cardboard creases easily. Make sure the crease lines are straight and lined up so the lid will fit cleanly when finished. Once the base is complete, repeat the same method to construct the lid using the slightly narrower strips.
Step 4 — Prime: Once both box parts are assembled, prime them if the cardboard has writing or printing. A white primer or base coat will help your final paint color apply smoothly and evenly.
Step 5 — Paint and finish: Paint your boxes however you like — solid colors, patterns, or color blocking all work well. I used a dry-brush technique to add subtle variation to the solid colors, but a few coats of even paint will also look great. Allow paint to dry thoroughly so the lid does not stick to the base.
Once dry, your letter boxes are ready to fill with party favors, treats, or small gifts. They make memorable keepsakes, and often guests are more impressed with the box than the contents. Enjoy making them, and have fun customizing colors and finishes to match any celebration.
All photos by Studio DIY
After making these letter boxes I started brainstorming other cardboard projects that avoid extensive fringing, for people who want simpler piñata-style alternatives. If you enjoy birthday DIYs, these letter boxes are a great place to start and can be adapted to many themes and styles. Have fun creating!