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Step 2Get some cardboard
By get some cardboard I mean get lots. Then get some more. This chair uses a huge amount of material and creates lots of scrap.
I started the project using 1/8 inch cardboard. This thickness is VERY easy to source and you'll be doing stores a favor by taking it off their hands. However, building up a 29 inch chair will take a lifetime. Do yourself a favor and take the time to find 1/2 inch cardboard used for watermelon or pumpkin bins.
Some stores are reluctant to part with these bins as they can be used with a shallow plastic tray insert to merchandise smaller produce. I had to check back frequently to my neighborhood market to get the bins as they emptied, but before they are crushed and sent to the recyclers. This generally means going to the stores early in the morning when the stocking is done. Be prepared to help the produce guys or gals move some melons to free up your bins.
I used about 8 of these 4' x 4' bins for my chair. Sourcing this many can take awhile so I would have to periodically use up what I had then replenish my supply.
A few parts of the chair benefit from thinner cardboard. The very first layer needs to be stapled or nailed to the jig and this is easier done with thin cardboard. As the top of the half-sphere is being completed the cuts will get less perpendicular to the curved surface and require a very shallow cut. Using thinner cardboard on these shallow cuts will take more time, but will be easier with a short blade.
I started the project using 1/8 inch cardboard. This thickness is VERY easy to source and you'll be doing stores a favor by taking it off their hands. However, building up a 29 inch chair will take a lifetime. Do yourself a favor and take the time to find 1/2 inch cardboard used for watermelon or pumpkin bins.
Some stores are reluctant to part with these bins as they can be used with a shallow plastic tray insert to merchandise smaller produce. I had to check back frequently to my neighborhood market to get the bins as they emptied, but before they are crushed and sent to the recyclers. This generally means going to the stores early in the morning when the stocking is done. Be prepared to help the produce guys or gals move some melons to free up your bins.
I used about 8 of these 4' x 4' bins for my chair. Sourcing this many can take awhile so I would have to periodically use up what I had then replenish my supply.
A few parts of the chair benefit from thinner cardboard. The very first layer needs to be stapled or nailed to the jig and this is easier done with thin cardboard. As the top of the half-sphere is being completed the cuts will get less perpendicular to the curved surface and require a very shallow cut. Using thinner cardboard on these shallow cuts will take more time, but will be easier with a short blade.
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