However, this chair has a number of notable failures. First, the paper-mache surface, while nice-looking, smooth to the touch, and durable, was a huge amount of work. In the same vein, an attempt was made to save labor by constructing the chair out of strips cut on a table saw; however, those time savings were negated by the need to miter every strip to fit into the cantilever profile. To tie the layers together in the absence of big clamps, threaded rods shoot through the whole chair in five places, which in many ways defeats the purpose of making a cardboard chair in the first place -- what's the point if you're just going to throw a couple of big pieces of steel in the middle of the thing? Last, the form is clumsy, with five-inch wide strips for strength making a big, bulky, and extremely heavy chair.
The goals for Cardboard Cantilever 2.0 were to address all of these weaknesses: made only from glue and cardboard, no paper mache or steel fasteners; cutting the strips without miters to save time; cutting the strips to length after lamination, also to save time; and attenuating the cardboard strips' width so as to make the chair visually lighter and more delicate.
In addition, I wanted to explore the idea of making multiple copies of the same chair as precisely as practically possible. To make multiple copies, the cost had to be kept to a minimum. To that end, the steel was eliminated, but also using commercial glue was out due to the volume needed. Instead, this chair was made with wheat paste, keeping the glue cost to an estimated two to three dollars per chair. The other issue with multiple copies was finding a way to make the lamination process more refined so the layers lined up better and were clamped under even pressure while the glue dried for maximum strength.
The finished photos below give a good idea of how this one stacks up next to Cardboard Cantilever 1.0, as well as scans of drawings I made to develop the form and the clamping jig. For an explanation of the ergonomics and physics of the cantilever form, refer to the link to the first Instructable.