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A cardboard shelf to fit a Benno Ikea cabinet with a pleasant appearance!

 
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Step 1: Materials

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corrugated cardboard, approximately 1/8" to 3/16" (free)
white posterboard (Dollar tree 50 cents)
white glue
fine pointed applicators (recommended)
scissors
paper cutter
xacto knife or CNC paper cutter
clamps
toothpicks
clamps (the more the merrier)
diagonal cutters

cutting and scoring patterns (attached)

Step 2: Cut and glue the cardboard interior

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cut two squares of cardboard exactly 6" x 6 1/4"



glue them together to create a square of cardboard approximately 3/16" thick and 6" x 6 1/4" in overall dimensions

Step 3: Cut the posterboard exterior

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using the MTC* file attached and a CNC cutter, cut out the green shape from a piece of white posterboard

score along the blue rectangles



*.mtc stands for "MaketheCut" software file format

Step 4: Fold the white posterboard finish

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Using mountain folds on all the scoring lines, pre-fold all the sides and tabs of the white posterboard shell

Note that on my CNC machine, the tabs don't always get fully cut out, so nip those with some scissors if you notice this happening.


Step 5: Glue the white shell to the cardboard interior

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These shelves have a "pretty" side and a less pretty side.  I  don't bother adding glue to the pretty side (as shown in video) so that it comes out smoother.

Watch the video for gluing instructions if you need them

Step 6: Make the shelf pins

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Each shelf needs four pins.

Cut a strip of white posterboard 1 inch wide and about 1.5 - 2 inches long.

Apply a thin layer of glue to the rough side of the posterboard..


Tightly roll the posterboard onto the wooden toothpick..

Clamp it and allow to dry for a while...


Step 7: Trim the shelf pins and adjust if needed

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Trim away the excess toothpick from the ends of the shelf pins using diagonal cutters.



Test the shelf pins to see if they fit in the holes, if they are too large, just peel off a little bit of paper, snip that off and try again.  See the video if you are not sure..

Step 8: Enjoy!

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Step 9: Parting thought

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Being made of cardboard, these shelves should not be exposed to moisture, so don't put them in a kitchen or bathroom or outdoor area....