Picture of How to make a corflute roller-shutter (or any other curved shape)
Update: I've published an instructable for the rest of the project here. This is also entered into the hurricane lasers contest.

This is my first instructable, and my first contest entry, so if I've done anything wrong, I appologise.
This idea (and the asociated tool design) was part of a GCSE tech project (tip for anyone doing a resistant materials exam; making your own specialised tool gets marks!)
The rest of the project is documented in this instructable

On my project, I decided that I wanted to have a roller shutter, like on old roll-top desks. However, to manufacture a traditional roller shutter would have taken too long. Therefore, I came up with the idea of using corflute (or correx, corriboard, etc). This has other advantages too:
It is recyclable
It is relatively easily cut
It can, if wanted, be signwritten
It is availiable from old "For Sale" signs

The technique I used could also be used to produce a neat curve from corflute.

Step 1: The Idea / Warnings

Picture of The Idea / Warnings
The Idea:
In order to make the corflute bend, I cut every other flute out of one side of the corflute

Safety Warnings: The cutter I made for this project used 2 scalpel blades. These are sharp, so be carful with them. (I know this is obvious, but I thought I'd better be on the safe side on my first instructable)
sbrown95781 year ago

what, no picture of the finished product?

osimmons12 years ago
Love the idea, planning to use the shutter in some home development. But I have to ask, where did you get the corflute? i have a found a couple places that sell twinwall polycarbonate but nowhere that sells it in colours?
I'm guessing since you call it coroflute you aren't in the US, we call it Coroplast. However, here in the States you can purchase this from sign makers.
Word to the wise, this stuff is VERY slippery, and most adhesives and paints don't stick to it very well. I find priming it with Krylon plastic specific spray paint does a good job of making it less unstickable.
mushroom glue (author)  Mugsy Knuckles1 year ago
I did find it pretty tricky to glue the handles on when I did it, as they did come off a few times. I wasn't planning on gluing anything to it, but I was running short on time to get it done.
mushroom glue (author)  osimmons12 years ago
I think I got it as a pack of 10 sheets from here. It only took less than a sheet to do the cabinet, but the other sheets have come in useful for other stuff around the house. The "short flute" sheets are the best to get for this, as the flutes go along the narrow edge of the corroflute, allowing you a longer shutter.
If you do use this idea for a project, could you put up some pics? I'd be interested to see someone else's take on this method.
This could be adapted to make roller blinds for a window too
mushroom glue (author)  marushkalynn3 years ago
Probably. You might get problems with the plastic fading though, as I'm not sure how good corflute is in full sun. Thanks for the comment.
ericCycles3 years ago
I love the concept! I wish I'd thought of something similar when I cut the twin wall polycarbonate glazing for my greenhouse.
However, if I understand the use of your tool, you needed to line the tool up very carefully with the corriboard at the beginning of each cut. If the vertically aligned part of your tool had a tongue protruding from it, of a size to just fit inside an uncut channel of the corriboard, you could just shove it into channel with no manual precision needed at all.
mushroom glue (author)  ericCycles3 years ago
I did consider this, but it would have to be mounted at the back, leading to problems getting rid of the cut corflute, so I stuck with this design. To be honest, It wasn't that hard lining it up, as the blades were 3mm apart and the flutes were about 4mm wide. Once I'd got used to it (and you get used to it pretty quickly after cutting that much corflute) It didn't take long to align.
dreamberry3 years ago
This looks so slick and modern! A great update on the old roll top idea!
mushroom glue (author)  dreamberry3 years ago
Thanks. I had considered going for a more traditional style of roller construction, but decided to do this instead, as it fitted better with the design, and was quicker to make (an important consideration when working to a deadline)
paintphone3 years ago
Wow really good idea here, Good use of the material. This Instructable shows us exactly what was done to achive the final product, including tools and making them, Great job,
mushroom glue (author)  paintphone3 years ago
Thanks. This was my first instructable, so I thought I'd better be safe than sorry and put plenty of detail in.
joelhunn3 years ago
Awesome idea! And something that a normal "handyman" like me can do. Thanks!
mushroom glue (author)  joelhunn3 years ago
thanks. A handyman with a laser cutter, anyway.
jmray3 years ago
Never thought of this - wonder how this compares to the fabric backed stuff? Is this what many of the political signs are made of...?
mushroom glue (author)  jmray3 years ago
yes it is what political signs are made of. I don't know how it compares to the fabric backed stuff, but it seems to work pretty well, and it was quicker to make.
rimar20003 years ago
Very interesting, thanks for sharing.
mushroom glue (author)  rimar20003 years ago
Great idea, and I love the tool you built. I really appreciate custom built tools.
mushroom glue (author)  Jason Bedard3 years ago
Thanks. I'm going to post write an instructable for the rest of the project soon.
I entered this in the hurricane lasers contest, so please vote for it!