Step-by-step instructions in today's post. This gusset style envelope is ideal for highly dimensional slimline cards.
I'm using P13 The Four Seasons - Autumn paper to create a slimline envelope featuring a 'button and string' closure, also called a 'string and washer' closure, with a gusset. My recipe uses one sheet of 12x12 double-sided patterned cardstock paper, linen thread, a charm for the end of the thread, and two eyelets. My envelope's orientation is a portrait format.
If the pattern/design of the 12x12 cardstock you are using looks better in a landscape format, just turn it one quarter turn from what is shown and proceed.
Start by cutting the 12x12 paper into two (2) 4-1/2 inch wide panels, with a leftover 3-inch panel (shown here on the left).
Trim one of the 4-1/2 x 12 inch panels to 9-1/4 inches (shown on the right), score the other 4-1/2 inch panel at 2 inches and 11-1/2 inches, and cut the 3-inch panel at 9-1/4 inches. Yes I wear camo crocks and an apron indoors lol.
Take the 9-1/4 inch x 3-inch panel to a scoring board and with right side of cardstock facing you, score at 3/8, 1-1/8, 1-7/8 and 2-5/8 inches. Flip over and score at 3/4 and 2-1/4 inches.
Cut in half at 1-1/2 inches. These are the gusset sides.
Adhere 1/4 inch wide Scor-Tape to the wrong side outer scored sections as shown.
Fold each in half along center score line, right sides together in a valley fold, and trim the ends at an angle as shown.
Complete folding along all score lines: mountain, valley, mountain - as shown; repeat with other piece.
Get the 4-1/2 x 12-inch panel with two score lines: adhere 1/4 inch wide Scor-Tape to the 1/2 inch section, and corner round the two inch flap. Scor-Tape is the best tape for creating envelopes in my opinion. It's an adhesive bond between paper so strong that you'll destroy the piece trying to separate joined papers.
If you are wondering why the panels vary in height by 1/4 inch (one is 9-1/2 inches and one is 9-1/4 inches) this is to ensure the flap closes cleanly. After making literally over a hundred of this style envelope I gladly pass this helpful tip on to you.
Get the 4-1/2 x 9-1/4 inch panel. Find half-way: 2-1/4 inches, and mark it.
Using a two inch circle punch, center on the mark and punch about 1/4 into the circle punch as shown. This is optional but adds a nice detail.
Adhere the two 4-1/2 inch wide panels together.
Find a leftover piece of cardstock and punch two 1-inch circles. I often use the obverse side of the cardstock for these circles if it helps with contrast against the envelope. Mark the center of one, hold together and punch eyelet hole through both (shown in photo). Attach charm to end of a 24-inch length of linen thread. I use a knot my grandfather taught me to attach a hook to fishing line. Google uni-knot. You want about 18 inches or more of linen thread length once the charm is attached.
Attach the 1-inch circles using eyelets: attach one 1-inch circle to the very center of the envelope flap first, then the second 1-inch circle to the body of the other panel second. The second 1-inch circle is positioned approximately 4 inches down from the panel top. I used a Big Bite tool for the second circle; alternately you could use a self-healing mat and eyelet setting tools.
Attaching gusset sides: Be vigilant of the gussets' pattern direction/orientation before proceeding. Remove one Scor-Tape liner from one gusset side and adhere to envelope. Tuck folded portion inside the envelope. Remove other Scor-Tape liner and attach to envelope, completing one gusset. Repeat for other side. Be sure to remove one liner of one gusset piece at a time to avoid heartbreak - to repeat, this adhesive is strong and repositioning is not an option.
If this step is confusing to you, please refer to this video, and start at 6:40.
Using the linen thread, tie a knot around the second 1-inch cardstock circle/eyelet located on the body of the envelope, being mindful to try and leave the shortest tail possible. Carefully trim tail of linen thread from the knot you created so the remaining tail nub is hidden under the 1-inch circle. Sweeeeet.
Completed slimline envelope with gusset featuring 'button and string' or 'string and washer' closure. Charms can be customized to the occasion, the recipient's style, or coordinated with the patterned paper.
This is a great envelope for highly dimensional slimline cards that are being hand-delivered, or enclosing with a gift in a corrugated box to be shipped.
This button and string or washer and string style envelope is not allowed to be sent as is through the United States Postal Service. I have used the gusset style and omitted the 1-inch circles/eyelets/linen thread/charm. I simply adhered the two inch flap closed using Scor-Tape, then addressed and applied postage stamps as the weight and surcharge dictated. The USPS surcharge (today is September 12, 2020; different USPS rules may apply in the future) applies for these envelopes due to their thickness exceeding 1/4 inch.
Think of it this way - you are not simply mailing a card, you are shipping an art piece.
Thanks for stopping by today!