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Cardboard Cantilever Chair 2.0

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In late 2008, the first Cardboard Cantilever Chair came into the world, wrapped in paper-mache and held together with five threaded rods: www.instructables.com/id/Cardboard_Cantilever_Chair/

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.

 
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collercoper9 months ago
Finished gluing my chair. Took a good 4 hours with help. Waiting for it to finish drying, I can't wait!
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Hell, I might try to make a decent looking bench from this...
I'm worried if my cat would use it as her new scratcher.
So? build a new one!
icekid2 years ago
That is so cool! Looking forward with building one.
sci53 years ago
Awsome chair, I made one for my physics project and it amazed everyone. Everybody in the school sat in it. We were amazed at how sturdy the cardboard chair was.
noahconlay4 years ago
 The beginning of my jig. Pretty close copy of yours, so a 0 on creativity haha. Base is 22", leg 16" with a17" seat and 2' back. The seat is an inch lower than the leg, the leg protrudes in front of the base 1" and the back of the chair protrudes 1" behind the base. Most of the load is above the middle of the base. I'm collecting cardboard, so project is on hold for now
 
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wholman (author)  noahconlay4 years ago
 looks good man, best of luck.  just pasted up some cardboard this afternoon, making my second chair from the pattern.
newroger4 years ago
muito bom adorei esta ideia!!!
theplatform4 years ago
 so. . . is it comfortable?
So how much would this chair weigh?
It weights about forty to fifty pounds
Doctor What4 years ago
 That's a great improvement!  I have to be honest, I would've never guessed wheat paste.  Ever.
I saw it a couple weeks ago...
I was just as shocked.
dkfa4 years ago
So if you just plopped down on it, it wouldn't break right? How much does it weigh. How fragile is it? How long would this take to make one the quickest way possible?
wholman (author)  dkfa4 years ago
 It flexes some, much like Frank Gehry's cardboard chairs -- it has been tested up to about 220 lbs.  The flex adds to the ergonomics in that it is a pleasant bounce, and the structure bounces back once the weight is removed.  It weights about forty to fifty pounds.  It takes about ten hours to make each one once you've made the jig.
theRIAA4 years ago
very nice
gdufford4 years ago
Nice chair! A good jig makes all the difference. It was the ONLY way to make my cardboard chair. I was tempted to use wheat paste, but was worried about drying time. How long did it take to dry each layer?

Also, check out my notes on working with 1/2 inch cardboard. It's much harder to get, but well worth the effort.
That is the most coolest use of cardboard i have seen . Must make.
carlos66ba4 years ago
Fantastic!  The chair looks quite nice and comfy.
pocketlama4 years ago
Neat and sweet, now I want one!
rimar20004 years ago
That's incredible, congratulations!
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