How to make DIY LUNAs from uncut sheet

Influenced by designs that have been around for at least 10,000 years in North America, LUNA's DIY Assembly Kit encourages the proud human tradition of making your own footwear.

Making sandals from an uncut LUNA DIY Assembly Kit is fun and relatively easy. Some tools are required, though the options for cutting and preparing these sandals are endless.

The uncut LUNA DIY Assembly Kit includes a sheet of soling material & laces. The laces are strong and comfortable. 

 

Instructions :: How to make LUNA Sandals from an uncut DIY Assembly Kit

Recommended Tools and Materials

  • Marker or pen
  • Two sheets of paper (for foot tracing)
  • Scissors
  • 3/16 inch leather hole punch (buy on amazon), OR 3/16 inch drill bit and drill (1/4 inch also ok)
  • Hammer (any normal hammer will work)
  • Utility knife or razor blade with new and sharp blade

Step 2: Trace your feet

Stand on a sheet of paper with your weight distributed evenly throughout your foot. Trace around your entire foot making sure to hold the pen perpendicular to the ground and not angled under your foot. When you finish tracing you should be able to look down at your foot and see the outline. Before moving your foot, mark the toe and side holes by drawing a small mark straight down between your first and second toes for the toe hole (you should be able to see the mark when looking down at the space between your toes).


Draw a line directly under your outside ankle bone (you don’t need the inside one even though it’s pictured). Your footprint should look something like this:

 


Repeat this step for the other foot. Then flip one over, put the tracings together, and line up the shape and the toe holes to see if your feet are different sizes. If the footprints are only minimally different you can just use the (slightly) bigger footprint and discard the other. Or you can use both of them and continue to the next step.

 

Step 3: Make a stencil cutout of your sandal

Take your footprint and draw the shape of your sandal around the tracing of your foot. Give yourself 2 to 4 mm (or as much as you want) of buffer for wiggle room. If you would like to have nicely shaped sandals here are a few tips:

Draw the line on the outside edge of your sandal stencil straight from the forefoot back to the curve of the heel. Doing this will give your sandal a nice shape and also give you some more room to fit the side hole.
Curve the arch edge of the stencil under your arch a little. If you have high arches you may want to curve in more, if you have flat feet you may not want to curve in at all.
Take your time to draw a good shape.

Notice that I have curved the line that I will cut out under my arch a little.

Next, mark the outside hole about ¾ inch above your outside ankle bone line and about ⅜ inch from the edge of the sandal outline. Use this mark as the center of your outside hole. Mark the inside side hole directly across from the outside hole mark you have just made. Again, about ⅜ inch away from the inside edge. (Use your best judgement when placing the outside hole. The best placement can vary depending on the size and shape of your foot. If the side hole seems like it needs to go more forward or back, move it.)


The blue is marking the places to be cut out.

I have drawn the side holes as an oblong shape that is ⅝ inch long and 3/16 inch wide. You will make these holes with the 3/16 inch punch later.

Step 4: Cut out your footprint

Cut out along the line that you’ve drawn as the shape of your sandal

.

Next, punch out the holes of this stencil with your hole punch. To punch out the side holes punch a hole at the top and bottom of the oblong hole marks, then cut out the middle section between the holes with your utility knife (more description on this below).

Step 5: Trace your footprint stencil onto your soling material

Use a marker (lighter colored or non-permanent is better) or pen to trace your footprint stencil onto the soling material. If you have a leather footbed trace it directly onto the leather. If you have a naked top kit trace it on the top side of the rubber. Remember to mark the toe hole and the side holes. If you are using one footprint be sure to flip it over to trace the other foot. Make sure your getting a right and left foot.


Step 6: Cut out your sandals!

Cut out your sandals on a cutting mat, cutting board, or any flat board that you don’t mind scratching or cutting into. Put a new blade in your utility knife. It’s a good idea to practice cutting some scrap along the edges before you start cutting out your sandals. Here are some tips for getting a clean and good looking sandal edge:

Keep the blade vertical at all times. It can be easy to angle the blade as you go around bends but try to always keep the blade perpendicular to the material.
Try to cut with long, continuous, smooth movements not short, jerky movements. The less you stop and start the better. It may take a few passes around before you get all the way through the soling material, especially with the 6mm Cherry and Leadville soling material.
It is best to cut on the inside edge of the line but if you start cutting astray it is better to cut outside of the line than into the sandal.
You can use some sandpaper (or a sander) to clean up the edges if you would like.

Step 7: Punch out your holes

Punch out the toe hole with the 3/16 inch leather punch. It can be helpful to practice punching a few holes in the scrap pieces. Be sure to punch the holes on your cutting mat or board.

 

Next, punch out the side holes by punching a hole at the top and bottom of the oblong side hole marks (optionally you can use a 5/8 inch oblong leather hole punch).
The sandal should look similar to this after all four holes are punched:
Now cut out the middle piece of material between the holes on each side with your utility knife.
Complete side holes:

Step 8: Lace up your sandals!

Follow this link for the LUNA Instructional video:

 http://www.youtube.com/watch?v=adS1hCuiTe4