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.

DIY Gingerbread-Man Door Decor
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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.

Life-size gingerbread man made of aluminum for your front door

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.

Life-size gingerbread man made of aluminum for your front door

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.

Life-size gingerbread man made of aluminum for your front door

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.

Life-size gingerbread man made of aluminum for your front door

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.

Life-size gingerbread man made of aluminum for your front door

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.

Life-size gingerbread man made of aluminum for your front door

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.

Life-size gingerbread man made of aluminum for your front door

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.

Life-size gingerbread man made of aluminum for your front door

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).

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