Step 1: List of Materials and Tools
1. Duct Tape
2. Poster Board
3. EZ felt (stiff sheet of felt)
4. 1" Elastic
5. Sticky Back Velcro
6. 3M Super 77 Spray Adhesive
7. Blue Painters Tape
8. Black sewing thread
1. Razor knife (x-acto or utility style)
2. Straight edge/ruler
3. Cutting surface/board
5. Hot melt glue gun
6. Sewing Machine
Step 2: Trim Poster Board
Trim the poster board to a size of 16 1/8" x 10". The poster board will be used as a core to make the folio stiff.
Step 3: Mark Spine
Mark the edges of the spine by measuring 7 3/4" from both outside edges to the middle. The spine will be 5/8" wide.
Step 4: Fold Spine
Score the spine edges and fold the folio like a book on the scored lines.
Step 5: Begin to Attach Duct Tape
Cut your first piece of duct tape longer than the width of the poster board. Attach to poster board at the bottom edge with approx. 1/2" overlap. Fold the overlap edge over onto the inside of the folio.
Step 6: Cover the Poster Board With Duct Tape
Flip over and continue to add strips of duct tape over lapping them approx. 1/4" until the complete sheet of poster board is covered. Take your time and fully rub down the duct tape as you go. When you get to the end fold over the opposite end like before.
Step 7: Cover the Inside With Duct Tape
This is almost exactly like covering the outside except begin the first row by leaving approx. 1/4 " from the bottom edge of the poster board to the edge of the duct tape.
Step 8: Trim Side Edges
Take note of where the indentation of the outer edge is in the tape. Trim both outside edges with the knife and straight edge.
Step 9: Fold the Spine
Fold and press the spine edges several times making them bend easier.
Step 10: Add Outer Edge Trim Strip
Cut a piece of duct tape longer that the height of folio. Attach to the outer sides (vertically) and wrap around edges. Then trim the ends to the top and bottom horizontal edges.
Step 11: Folio Main Section Complete
Folio main section complete
Step 12: Make Closure Strip
Cut 2 strips of Duct tape 5 1/2" and 3 3/4" long. Attach both strips with adhesive sides together overlapping one end of the shorter strip by 3/8".
Step 13: Attach Closure Strip
Attach the closure strip to the inside right (iPad side) at the vertical center. Be careful to match adhesive end and outer edge on the back side. Place an extra strip of duct tape approx. 5" long vertically over the area where the closure strip attaches to the folio.
Step 14: Trim Easy Felt
Trim Easy Felt to 9 1/2" x 15 1/2" rectangle. This is the inside liner.
Step 15: Check Felt and Fold Spine
Check fit of felt inside the folio. Proper fit will have 1/4" exposed edges of the folio all around. Once in place use the fold lines on the outside exposed edges of the folio as a guide to crease/fold the felt at the spine.
Step 16: Cut Strips of Elastic
Elastic is used to secure the iPad to the folio. Cut 4 strips of elastic at 3 1/2" long.
Step 17: Attach Outer Edge Elastic Holders
Set the first strip of elastic diagonally across the outer corner on the top right (iPad side) of the felt. Leave 1/4" of the edge and bottom of the corner exposed. Hold in place and turn over to the back side of the felt. Fold the remainder of the elastic over and hot glue in place. Be careful not to use too much hot glue because it will seep through the porous felt onto the underside of the elastic. Repeat for the opposite outside corner.
Step 18: Attach Inner Edge Elastic Holders
Attaching the inner elastic strips is similar to the outer except you first have to cut a slot for the strip to pass though the spine side. Measure 1/2" from the top edge of the felt. Start at that mark and cut the slot along the spine fold 1 1/4" long. If you have a hard time seeing the fold line it's 7 1/2" from the outer edge.
Slide the elastic strip through the slot at an angle and attach to the felt with hot glue the same as before.
Step 19: Further Secure Elastic to Felt
Hot gluing the elastic is really more to hold the elastic in place. To really secure it, stitch it to the felt with a sewing machine. Make the stitch diagonally from corner to corner using inner edge of the elastic as your guide. Be careful not to catch the top side of the elastic in your stitch. Repeat for all 4 corners. Once the stitching is done trim the excess elastic from all 4 corners.
Step 20: Attach the Felt Liner to the Folio
Use spray adhesive to attach the felt liner to the folio. I mask off the outer edge top side with 1 1/2" blue painters tape to keep the over spray off the top side edges of the felt. Spray the underside with a good amount of adhesive. Avoid the spraying adhesive on corners where the elastic is attached.
Set the felt onto the folio paying close attention to the line up at the spine. Once the felt is pressed and secured hot glue all 4 elastic corners into place. Don't over do the hot glue but be sure they've boned well.
Step 21: Affix the Closure Strap With Velcro
Once all the glue is dry. Slip the iPad into the folio. Cut a 1" x 1 3/4" piece of sticky-back velcro. Attach one side of the velcro to the back side of the closure strap. Peel the opposite side of the velcro. Wrap the closure strap over the side and front of the folio pressing the velcro into place.
Step 22: Done!
Congratulations you're done.