Upon seeing how cool my pocket protector was, everyone else at Instructables requested that I make some for them.
In short, making your own pocket protector will turn you into a very popular person.
Disclaimer: Melting vinyl or plastic may be toxic and should be done in a well-ventilated area. Do this at your own risk.
Step 1: Go Get Stuff
- a 3-ring binder with a vinyl cover (as pictured)
- or a vinyl term paper cover
- a plastic bag sealer
- or a soldering iron and some wax paper
- a laser cutter
- or ink jet printer
Step 2: Start Cutting Up the Binder
Trim excess plastic around the sealed edges.
Step 3: Remove the Cardboard
Pull the cardboard out through this opening.
(Don't do like I've done in the picture. See picture comments for more info.)
Step 4: Cut the Vinyl Some More
At this measurement, cut across the vinyl so that you produce a folded-over strip that is 3-3/4" wide and about 10" long.
Cut 3" off the strip so that it is 7" long (folded in half), but do not remove the side where the edge is still sealed.
Next, cut away the sealing joint that runs lengthwise down the strip.
You should now be left with a folded strip that is 7" long, a little under 3-3/4" wide and is folded over at the bottom of the shorter side.
Step 5: Fold.
Once you are sure the fold is correct, run your thumb back and forth over this crease a couple of times while applying a strong pressure.
Step 6: Seal
Place the edge of your protector on the heat sealer so that the edge of the heat sealer lines up to the crease that you just made (see pictures).
Seal for three seconds (or as necessary. I recommend doing test seals.)
If you are using a soldering iron, sandwich the protector between the waxy side of two sheets of wax paper. Trace the edge of the protector from the crease that you folded to the bottom crease using the soldering iron. This may take some testing before you get it right.
Step 7: Some Final Modifications
Carefully and slowly round of the corners of the top side and the front flap with a pair of scissors.
Trim any excess material that may be sticking out from the side of the case.
Step 8: Finishing Touches
I decorated mine with a Epilog laser cutter (settings: Raster cut. Speed = 100%. Power = 30%).
You can also try running it through an ink jet printer. However, you might have had better luck printing on the pocket protector material from the onset (before you did any folding, sealing or cutting).