10. Here is a #7 USPS Priority Mail Shipping container. The box is still flat, and it needs to stay that way. I go through a lot of these, but at least they're free. |
11. Using a utility knife and a 1/4" thickness of masonite as a straight edge, I split the box open at the cardboard flanges so that I wind up with two sheets roughly 20"x24". |
12. I'm going to laminate the two sheets together. But I turn one of them 90° so that its "ribs" are at a right angle to those of the other sheet. This increases the strength of the cardboard sandwich I'll be making. Where you see my right hand holding the piece that sticks out 4" from underneath, I'll cut this off and use it to make up the difference on the side. I'll tape and glue the loose pieces together. Elmer's is good, but spray-glue is also a good secondary option. |
13. A 1/4" thick sheet of masonite, cut to 16½" x 20½". I use this as a cutting template for the cardboard sandwiches. |