Step 1: Materials and tools
You'll need the following materials:
- Scrap Cardboard that is about 15" x 29" (I had scrap cardboard from a bath tub that I installed a while back, but you can also use wine boxes or large boxes that you can get for free at sam's club/costco)
- Glue (Either yellow wood glue or white glue)
- The blueprint below.
- Measuring tape
- Straight edge
- Razor/utility knife
Step 2: Layout
Square up the cardboard using the corrugation marks on the face of the cardboard. And then start to layout the cuts and folds on the cardboard blank. Double check all your measurements and layout marks. I even messed up on this and didn't layout the top of the box correctly. Live and learn.
Step 3: Cutting
One other note, when looking at the blueprint, the bottom part marked "first", has a dotted line 1/2" from the bottom. It is highly advised that you first cut up to that half inch line instead of cutting the whole 1" section out, here is why. When I made the first couple of boxes, I noticed that my cutting, but especially my folding was not spot on. And the 1" gap, ended up being to big of a gap, with little support for the "third" section while test fitting before glue-up. So by starting at 1/2" up, you give yourself a better chance at a tighter fit on the bottom.