Cardboard Lumber

How would you like an incredibly strong, cool, and cheap building material for making lightweight tables, chairs, shelves, or anything else you can think of. Reusing cardboard to make furniture has always been a good idea, but the results I've seem have been either incredibly complex, or shoddy looking.

By laminating sheets of cardboard together into a large block and cutting this up with a table, or circular saw, you can create cardboard lumber of any dimensions you want: 2x4s, 2x8s, 4x4s. If you alternate the grain of the corrugations you can create plywood. If you glue your lumber together end-to-end you can create strong honeycomb-like boards.

You will only need three things to create cardboard lumber:
1) A Saw
2) Lots of cardboard
3) Glue... lots of glue

Step 1 Types of Saws

Table Saw: The best saw you could possibly use to do this is a table saw. You can adjust a table saw's fence to help you cut perfectly uniform lumber out of your cardboard block. This allows you to easily mass-produce cardboard lumber. Because of a table saws fence, you should be able to cut lumber twice as thick as the max height of your blade by cutting once, and then flipping your cardboard block over and cutting through entirely.

Circular Saw: If you're really good at cutting straight lines and have no other option then I guess you could give it a try.

Hand Saw: Possible, but too labor intensive for me.

Band Saw: If your band saw is as powerful as a circular saw than go for it, this could open interesting options.

Chain Saw: Messy...

No Saw: Unfortunately for people without access to saws, this instructable is not for you. I know it looks cool and all, but it's just not gonna work out.

Comments

[Mr.Miz]

Lumber in Colorado is expensive. Good hardwood is hard to find. I've read all the comments so far and I'm probably too far down the line for my comment to even get read, but I think the real value here is for making models. I'm a pretty below average wood worker. I can't tell you how much expesive lumber I've messed up learning. If I start using cardboard instead of lumber I will save myself TONs of money and it gives me a VERY abundant material to work with. THANK YOU this is VERY helpful and a wonderful idea.

[paulzef]

I agree with you. I live in Aus and I'm only a first year uni student, I can't exactly afford to go out and buy hardwood or lumber, so why not reuse the 3000 cardboard boxes that my neighbours throw out everyweek; not to mention I work in a supermarket and everynight there are 3 large (2 meter cube) bales of cardboard that just gets sent off for recycling without any monetary gain, I doubt my work would care.

[extrordinary1]

In the movie Lord of the Rings, the entire Shire Village was constructed from cardboard. All the homes were built with carboard. I think it was in New Zealand where they constructed all of it. Now i am provoked to build a cardboard electric tri-hull pontoon boat for fishing and recreation! Conv. stores get a lot of cardboard too. Every week they throw away a lot of card board. I worked at a chain that has over 50 stores now. 9 years ago, there were only 7 stores. Wonder if I can design a trailer too from cardboard. I think I'll use the expoxy for extra strength. I've tried cardboard stuff in the past, but my results were poor. Thanks for this instructable!

[theRIAA]

You're welcome, it sounds like you're on the right track to becoming a great woodworker. and don't worry, new comments automatically go to the top.

[micraman]

Great ible! Love laminated cardboard. But I am a little skeptic about the strength of the wheatpaste... I made a tiny bottlecap full and it seemed pretty sticky but doesn't feel as hard as glass like you say. Is it waterproof?

[sonipitts]

Actually, dumpster diving is NOT a crime in most areas, as long as the dumpster is not on private property, locked or fenced up. YMMV, depending on where you live, but the law generally considers trash to be abandoned by the owner and therefore free game. OTOH, most cardboard storage dumpsters are going to be on store property. So ask first, and leave the place at least as clean as you found it, if not more so.

[flamekiller]

This. For example, LE can look through your trash without a warrant once you put it on the curb. By the same token, if the cardboard bin isn't in an area that's off limits to the general public, you're more than likely good to go.

That said, to avoid any problems, just ask the store.

[hardlec]

There is a product called PC Petrifier that is designed to restore dry rot. When applied over paper or cardboard, it makes the cardboard much sturdier. In the Victorian era, Boiled Linseed oil was used to reinforce paper machie. I'd like to know more about either, but I really like the idea of using cardboard. What is the cost ratio to wood when all the glue is taken into account?

[Sequimania]

I've used a product called Wood Hardener on all kinds of weakened/open-grained wood that was either too valuable or difficult to replace. Love it but I think cardboard might soak up an awful lot of this stuff and it isn't cheap.

Boiled linseed oil used to be used as a finish for antiques but I've heard that it isn't recommended any longer. It does have a strong smell that lingers, sometimes for years.

A neuron just fired - Is there a new type of boiled linseed oil on the market that dries faster and has anyone used it?

[avatar_i]

Try going to your local hardware store and look for "HOMER FORMBYS FURNITURE FINISH".
I have been using Formbys for about 30 years in place of boiled linseed oil on anything I do with wood, if I want to have a durable finish.
There is nothing wrong with B.L.O., but Formbys gives you a hard waterproof finish that brings out the grain/colour of the wood, like B.L.O., with a matte varnish-like finish.

[Sequimania]

I've seen this in stores. I usually use a mixture of 1:1:1 mineral spirits, BLO, and denatured alcohol to restore a wood finish. After that any top coat can be used.

I restore antique sewing machines. In the interest of historical authenticity it is generally preferred that BLO is the final finish on the box-case-treadle stand. Unless they are for my own use and then, depending on how accessible they'll be to company, I choose btwn BLO and a satin poly. I've been wiping the poly on with a clean rag and it gives a nice finish.

Thanks for the tip.

[theRIAA]

I guess I paid $8 for flour, but I wasted a lot. I think they have a different starch glue that they use that is much cheaper though. A much sturdier stool could be made from $3 worth of 2x4s.

[precipice]

harika tebrikler..

[rrrmanion]

hard as glass? technically, glass isn't hard, because in fact, glass is a liquid... though this may just be an expression, but i've never heard it.

[chello2k9]

Glass is a liquid....ok.

[rrrmanion]

glass is what's known as a super cooled liquid. if glass was a solid, it would be opaque.. apparently anyway..

[starfox365]

Well, glass is CAPABLE of being a liquid. If it's melted down to extreme temperatures, it becomes like a gooey lava. I've seen glass blown before, and it's quite the site, seeing how pliable glass can be before suddenly becoming a solid to be reckoned with. :3

So, really, glass is a liquid. Until it becomes a solid. Things can change category, just as the 'liquid' form of water is water, and 'solid' is ice, and 'gas' form is mist/steam.
Many things have the range of becoming all three. :D

http://www.glassbirds.com/iittala-glassworks.html

[rrrmanion]

it's called molten glass when it's melted down

[crowd9]

Actually, diamonds are solid and transparent. Glass flows in cosmic time, inciting this age-old debate. For all intents and purposes, glass is a solid (unless you have a century-long slow motion camera), additionally, glass is definitely harder than other substances--hence, it's capability to cut those other substances.

[rrrmanion]

well, i wasn't fussed about rate of flow, but thanks anyways, insightful

[112251919112]

Thats like saying that everything solid is just a super cooled liquid, not a solid,

[Bob_of_Mars]

I'm afraid that is not true. Here, allow a physicist to explain:
http://www.youtube.com/watch?v=Omr0JNyDBI0

[rrrmanion]

well, some say it is, others that it isn't, I like the idea that it is because it's sound cool.

[XTL]

Actually just because a number of people have made a mistake and believe something to be true, when it is not - doesn't make it a type of true.
Or in other words "Endless repetition of a lie - does not make it true"
Just as when people talk trash about you - it doesn't mean its true.

In this case Glass is a solid (when it cools). Many materials are transparent and the video from sixty-symbols (above) explains why.

Glass also has a very special property and its why its called Glass. Generally when materials cool and harden into solids they form regular atomic structures - like Crystals. In fact all metals do this and is why they are called metals. Glasses do not form regular crystal-like structures. Instead their structure is more random and locally connected. This is why it forms sharp edges and irregular shards when it is broken.

Try listening to this explanation. http://www.youtube.com/watch?v=2Fk3y_lPr6Q

[redcore4]

could you use water-based varnish to stick the layers together? i have lots of varnish kicking about at home but no glue!

[ArtsyFartsyGirl]

Great ideas, but if I 've got to get sawdust and mix with glue, etc,etc, that would kill the thrill for me. I thought the idea was cardboard, not permanent construction. And yes I know its for added strength and durability, yada,yada! Maybe I'm just too lazy for all that!

[99Samus]

Can you get splinters from this? I'm scared to do this right now because of my phobia of splinters

[pdub77]

Working with cardboard every day I can safely say that splinters are not an issue to be concerned about. PKTraceur has a point, though. I have been the recipient of a cardboard 'paper' cut. It was not fun, but no more of a problem than any other paper cut. Just be careful and you will be fine.

[Sequimania]

Ha ha! Cardboard should be perfect for you.

[PKTraceur]

No offense, carboard splinters? I think my main worry would be paper cuts... :)

[theRIAA]

no, but the glue makes the cardboard hard, and could be sharp.. no splinters though.

[kgrove-1]

For everyone saying just use wood, that is for ppl who dont care about what materials they need just the end project which is fine. I, on the other hand am in a competition to make the most epic house out of cardboard only to win a cruise and to help raise homeless awareness so this is perfect!!!!

[pdub77]

I would love to see what you are doing and any progress you care to report. Message me if you are willing. I am very curious.

[Almasy]

has anyone ever tried using a router to cut the cardboard? Just curious if the shape of the bit will hold or if it ends up looking like crap.

[nate71173]

while i wouldnt build furniture with this stuff, it is interesting for crafts, and maybe fashioning some organizational tools, and whatever else. good idea. id also like to point out that if you were to take this to a conventional RECYCLER, it would be milled down to a pulp, and be combined with MORE glue (than u used) to make paper, and...... MORE CARDBOARD! all u people citing the terrible use of glue need to think about it before you condemn it.

[Sequimania]

There are companies that specialize in furniture made out of cardboard. Couches, chairs, tables, bookshelves, you name it. More popular in Europe I think. It is very sturdy and when one tires of it or the dog takes a liking to the glue that's been used it can be recycled.

I recently found out that you can fuse fabric to paper with fuse-able interfacing (sewing store). Don't see why you couldn't fuse fabric to cardboard if you were using it for furniture. For that matter you could just glue it on after fusing clear vinyl to the right side of the fabric. (Fuse-able clear vinyl = sewing store.) I think it comes in matte as well as shiny vinyl.

[fzumrk]

If you are going to make a structure out of this and want to waterproof it and or fireproof it, how about this: Just treat it like it is a normal wood structure. For garden sheds, they typically are not fireproofed in any way, so I don't know that you have to worry about it. If you do want fire resistance, you could drywall the inside of the structure. This is all that residences use for fire protection.

For outside water protection, ice shield or another type of adhesive roofing membrane would probably work. Roof edges would still need flashing as this is the most likely place for water to get in. You could make flashing out of recycled aluminum if you are trying to keep the project green.

Walls could be waterproofed like normal residential walls: Tyvek and adhesive flashing around around openings. I'm not sure how you would fasten the Tyvek to the cardboard though.

I wonder if you could make your own insulated structural panels like this? You could build them with a layer drywall on the bottom and a layer of plywood on top with multiple layers of cardboard in the middle. They might be too heavy to handle though.

[quark43]

if you painted it with Kilz or regular paint would that waterproof it. Im thinking of building a shed with this. thanks for the ideas

[rrrmanion]

i would put layers of plastic in somewhere, or put wayyy too much glue on the outside layer(s)

[glorybe]

Paint and other surface finishes do little to stop water intrusion. There are leak sealers that might work. Fiberglass and resin are known to work well as is sheet metal.