The cardboard I chose was from shoe boxes. It was thin corrugated cardboard with a thicker, nicer looking presentation side.
Step 1: Step 1
Trim a pencil and cut a notch into the bracket about a third of the brackets width. Cut these notches to fit the pencil as tight as possible. Add another layer of cardboard to each side to cover the notches. Once the glue dries, trim the brackets to 1” (25mm) thickness.
I know its a bit of a cheat using pencils as struts but i didn't have enough cardboard to make them. I'm confident 1” wide cardboard struts would work instead of pencils.
Step 2: Step 2
Step 3: Step 3
Step 4: Step 4
As a finishing touch, cut out the recycle logo from the cardboard box and use it to cover the unsightly joint where the back brace meets the bracket. And of course, add an instructables.com sticker from a prize pack.
- Use 8-10 books to press the pieces down when drying. This should be enough weight to press the pieces together without crushing the corrugated sections while the glue is drying.
- If you don't have a Try Square use the corner of a table, book or CD case to make sure the parts are as square as possible. Tape the CD or table corner to the parts while its drying so that it dries square.
- If you don't have a drill, use a nail to pre drill the holes in the back brace when screwing it to the brackets.