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Make a Life-Size Gingerbread Man Cookie Cutter
Traditional holiday door decor gets a playful upgrade with this charming DIY aluminum gingerbread man that resembles everyone's favorite seasonal treat.
Materials Needed
- 2 pieces flat bar aluminum stock (1 1/2" x 1/8" x 96")
- (4) 12" clamps
- 5-gallon bucket
- 1-gallon paint can
- 1/2" self-drilling screws (#8 pan head Phillips)
- cordless drill with Phillips bit
- 7/64" drill bit
- winter scarf
Create Head
Center one piece of aluminum stock above a 5-gallon bucket, then bend around it to create the head. Use a clamp to bring each side back together at the neck.
Step 1: Create the Head
Center one piece of aluminum stock above a 5 gallon bucket, then bend around it to create the head. Use a clamp to bring each side back together at the neck.
Photo by: Flynnside Out Productions
Flynnside Out Productions
Bend Outward at Neck
Underneath the clamp, bend each side back out to create the top of the arms.
Step 2: Bend Outward at Neck
Underneath the clamp bend each side back out to create the top of the arms.
Photo by: Flynnside Out Productions
Flynnside Out Productions
Finish Arms
Approximately 12 inches down from the neck, place a 1-gallon paint can and, using your foot for leverage, bend stock around it to make the hand and bottom side of the arm. Repeat on the other side.
Step 3: Finish Arms
At approximately 12 inches down from the neck, place a 1 gallon paint can and using your foot for leverage bend stock around it to make the hand and bottom side of arm. Repeat on the other side.
Photo by: Flynnside Out Productions
Flynnside Out Productions
Tighten Neck
Once the arms have been made, set the gingerbread man on its head and push stock together at the neck. The top of the gingerbread man is now complete. Set aside until later.
Step 4: Tighten Neck
Once the arms have been made, set the gingerbread man on its head and push stock together at the neck. The top of the gingerbread man is now complete. Set aside until later.
Photo by: Flynnside Out Productions
Flynnside Out Productions
Start Legs
Take the remaining piece of aluminum stock and bend sharply in the middle by stepping on it or using a clamp. Once bent in half, it should measure 4-feet long.
Step 5: Start Legs
Take the remaining piece of aluminum stock and bend sharply in the middle by stepping on it or using a clamp. Once bent in half it should measure 4 feet long.
Photo by: Flynnside Out Productions
Flynnside Out Productions
Bend at Feet
Measure 12 inches down along the bent aluminum stock and bend outward around the 1-gallon paint can to create the foot. Repeat on the other side. The bottom of the gingerbread man is now complete.
Step 6: Bend at Feet
Measure 12 inches down along the bent aluminum stock and bend outward around the 1 gallon paint can to create the foot. Repeat on the other side. The bottom of the gingerbread man is now complete.
Photo by: Flynnside Out Productions
Flynnside Out Productions
Bend Top of Legs
Measure and mark the outer leg 4 inches down, then use a clamp to bend the stock outward at 90 degrees. Repeat on the other side.
Step 7: Bend Top of Legs
Measure and mark the outer leg at 4 inches down, then use a clamp to bend the stock outward 90 degrees. Repeat on the other side.
Photo by: Flynnside Out Productions
Flynnside Out Productions
Join With Screws
Pre-drill holes through the overlapped pieces of stock and join together using pan head screws. Repeat on the other side.
Step 8: Join Top & Bottom With Screws
Pre-drill holes through the overlapped pieces of stock and join together using pan head screws. Repeat on the other side.
Photo by: Flynnside Out Productions
Flynnside Out Productions
Finish With a Scarf
Add festive color to your gingerbread man by tying a scarf around his neck (Image 1) before hanging on the door (Image 2).
