Here is my entry for a padded laptop sleeve that recycles a sheet of foam packing material and uses about a half a roll of duct tape. The project only took about 2 hours and the end result is a pretty sturdy cushioned sleeve perfect for your eeepc or any other laptop you want to protect.
Step 1: Materials List
Cutting knife ( I recommend a snap-off blade knife)
Sheet of foam packing material (I recycled mine from a package I received)
Step 2: Sizing the Cushion Liner
I cut the packing approximately the width of the original case, maybe slightly wider. Since I was recycling the foam I did not cut away from the length. In fact if I were to do this again, I would use a longer piece of foam to create a longer flap.
Save any excess you may have. The strip I cut away was used later to pad the sides of the bag.
Step 3: Laying Down the First Tape Layer
I measured the foam and decided to make this base layer of tape about 2 inches wider on each of the long sides and about 4 inches longer either end. The tape has to be laid out sticky side up and I just use a piece of masking tape to hold the ends down.
I overlapped each strip about 1/4 inch.
Step 4: The Next Layer
The next layer of tape sandwiches the foam in between. This second layer of tape should be laid out in rows with about 1/4 overlap and they should run perpendicular to the first layer.
I completely overlapped the sides of the first layer but stopped at either end at the edge of the foam.
Step 5: Sizing and Trimming
Then I made a final trim to the top and bottom edges and then then folded them down.
Step 6: Building the Side Panels
The side panels are composed of 2 strips of duct tape on the exterior side, overlapping again by about 1/4 inch. Then turn the whole thing over and place one strip of tape down the middle.
Step 7: Joining the Side Panels to the Main Body
I cut the side panels at an angle to main body and then stuck them to the main body. I reinforced the joints and created a channel that I could insert a piece of padding. I then laid a layer of tape from one side to the other making sure I had enough tape overlapping on either end to fold inside the bag. I made sure that this piece of tape was a continuous strip.
For the first step, crease the exposed edge of the tape on the side panel keeping the sticky side up, and then join it to the main body of the bag where the cushioned edge starts. Do this on both sides and you'll end up with what looks like an opened lidded box. At this stage, reinforce each seam on the inside of the sleeve with a strip of duct tape folded in half along its length.
Then crease the other exposed edge of the side panel and join it to the front of the sleeve. Do this for both sides. Reinforcing these seams is a bit harder but if you use a ruler to hold the tape, it can make this step a little easier. If you end up with a few wrinkles, no one will see them anyway.
Then attach a long strip of tape around the the sides to reinforce everything and neaten up the sides. You may have to apply a few pieces here and there to clean up everything.
Step 8: Final Steps
As a finishing touch, I added snaps to the flap. I did this only because I thought the flap was a little too short. Snaps are available at sewing notions stores and I used heavy duty snaps suitable for denim, etc. To install snaps follow the instructions included in the package. I also put a piece of tape over the back of each fastener (inside the bag) to protect my laptop from being scratched.
When I make my next sleeve I'll make sure it has a longer flap and I'll post photos to this instructable.
Thanks for looking.