Cardboard Storage Shelf From Single Box

I received a package in a big cardboard box, and I decided to transform it into a 4 shelves storage shelf unit. And if you think cardboard is weak, I'll prove you that you can put a lot of weight on each shelves. Now, let's get started!

Supplies

For this project, you will need :

- A big cardboard box

- Hot glue sticks and a hot glue gun

- An utility knife

- A ruler

Step 1: Cutting the Legs

The first step consist of cutting the four legs of our shelf unit. I cut the legs using the corners of the box. There's four corners and we need 4 pieces so it's perfect! Each legs are 4 cm x 4 cm x 84 cm

Step 2: Cutting the Shelves

In the last step, I've cut the legs out of the cardboard box. That made some left overs and I'm using the sides of the box to make the shelves. I cut two shelves from each pieces. There is one side on each shelves that is already folded, I'm going to do the same for the 3 other sides of the shelf.

Step 3: Cutting Each Shelves to Size

Before I bend the 3 other sides of each shelves, I cut some extra cardboard on each sides, then I cut the corners so it's easier to fold the shelf in the next step.

Step 4: Bending the Sides of the Shelves

One side is already folded, so I bend the 3 other sides by applying a lot of pressure on the line using a big metal ruler. That way, it's easier to fold the cardboard right on the line. So i fold the four sides of each of the four shelves.

Then, I put some painters tape on each corners so they stay temporary in place while I put some hot glue on the inside of each corners of each of the 4 shelves.

I now have four shelves but there still some work to do to make them heavy duty.

Step 5: Reinforcing the Sides

I add a piece of cardboard on the inside of each sides of the shelves to add some strength to the shelf, especially because the lines in the cardboard are on the horizontal instead of vertical, so it's weaker without the cardboard reinforcements I added.

Step 6: Reinforcing the Middle of the Shelf

Now that the sides of each shelf are build tough, the middle is still weak and to fix that, I'm adding a center brace and four smaller pieces to add some strength to the core of the shelf. Trust me, it will be able to take a lot of weight for a cardboard shelf.

Step 7: Fixing the Legs of the Shelf Unit

Now that the four shelves are done, it's time to add the legs. I first glue in place two legs, on one side, on the bottom and the top shelf.

Step 8: Fixing the Legs

Then, I glue in place the last two shelves, then I complete by gluing the last two legs in place.

I want my shelf to take a lot of weight, so I'm reinforcing the inside of the legs between each shelves.

Step 9: Finish Result and Load Test!

Time to test the build, I tried with 133lb total (60kg) of weight and it pass the test easily. I plan to use this shelf unit to store some computer pieces inside a melamine closet unit.

And the beauty of this build is that it's almost free to build, you just need a couple of hot glue sticks and voila!

Thanks for watching, if you like this project, please check my youtube video. Thank you!

Step 10: Youtube Video Tutorial

If you would like to support me and my work, the best way it by watching my youtube video! :-)

Thank you everyone for the support, I'm working hard to bring you more cool cardboard projects!

Comments

[aribet]

Wow, great idea! I have a lot of cardboard accumulated during the pandemic.

[Antonio C.M]

Fantastic idea!

[Waystation49]

Great idea! A slow paced video would help. Record a narration. If you use Zoom you can get a transcript.

Your written explanation here ? I can't follow it. It comes off like IKEA instructions- just figure out by logic vs instructions.

It seems you left out talking about many steps.

Can you also give measurements in inches please .

[ScienceDiscoverer]

Please, understand that not all people are hypersocial like you and many can be not comfortable to talk on camera.

And also, please, can you learn to use measurment system that 99% of the world uses and stop screwing up most of the world population with your stupid system of measurments?

[Waystation49]

I have rulers with metric and imperial. I use both. I am one reader. Many readers here use imperial. I agree: US and other places using imperial should teach it in school so we all get on one system. But then again, I also like the thought of a one-currency system, and one electrical current, too. We almost have one dominant world language. I would have favored French. English took over...

Still "slower and simple easy to follow instructions " can build a strong following.

"You" don't have to talk on videos? Can you write down what you would say and let someone else read it while you do the work? OR read it in to free recording software after the video is done. (voice over), or do voice over Power Point of slides of the steps.

It doesn't have to all be you. Public Speaking is the #1 fear in the world. Many people have no desire to talk in front of an audience. You don't have to change you, and you could ask others to join on your team you create.

Why bother? Build a following and passive income will follow. People selling online can earn over $2 million/ year US after about 2-3 years if they stick with it.

[JohnW51]

You can get a ruler that has inches on one side and metric on the other side. Actually, the metric system is much easier when doing this kind of project because you rarely must deal in fractions. A millimeter is very small, less than a 16th of an inch. (I am more accustomed to the Imperial system, but, as an engineer, I've had to deal with metric system a lot and have come to prefer it.)

[gravityisweak]

Step 10 has a 4 minute video.

[StephenB276]

A bottom layer of cardboard on the shelves would make it a torsion box design, which has even greater bending and twisting strength.

[JohnW51]

Yup. But he'd need another box. :-)

[ddulsky]

I love CTG technology (Cardboard, Tape and Glue). Nice engineering in your project.
I would just like to give a mention for new folks to be careful when cutting cardboard.
1. Use a sharp blade (safer to use than a dull blade). Sharp blades = less pressure needed
2. Make sure you are cutting on a protected surface, like a cutting mat or extra scrap cardboard. This helps keep your blade sharp.
3. I like to make a light first cut to break the top paper, then follow with one or two heavier cuts to get through the cardboard cleanly.
4. Always keep your holding hand and fingers "behind" where you are cutting. It is very easy to slip with the knife. If you are pressing hard, you slip far.
I see no bandaids on your fingers, so good work!

[JohnW51]

Good tips.

[Hey Jude]

You may like this:
http://www.judepullen.com/designmodelling/card-tec...
and this
http://www.judepullen.com/designmodelling/trickets...
if you'll forgive the shameless plug. ;o)

[leshemeli]

I liked it. You used all the right mechanical rules for getting the strongest profile with the minimum weight.
You shoul be an aeronautical designer.

[bliptrip]

For those of us that aren't mechanically trained, what is a good resource on finding the 'right' mechanical rules? Is there a simple set of rules, or is this more complicated?

[JohnW51]

You want to transfer the load to stiff vertical members. Wood and similar materials (like cardboard) are strongest in compression. So the horizontal load of the shelves must be transferred to the vertical "legs" in this design. Of course the shelves themselves must be strong enough to support the load without sagging or collapsing. This is accomplished by making the shelves with some depth then adding the vertical members under the shelves. These members stiffen the shelf so it can hold the load.
This is the same concept in wood frame buildings. The outside walls, and sometimes also some inside walls, support the roof. The walls are strong because they are "in compression", that is the 2x4s (or whatever the walls are made of) are vertical, their strongest orientation. Think about a thin piece of wood. If you lay it horizontal and press on the middle, it will bend. But if you stand it up and press on the end, all you get is a sore hand. :)

[leshemeli]

Hi, I tried to find something in the internet for you.
failed.
Keep trying. The mechanical engineering if a fascinating proffession.

[JohnW51]

Nice! Good job on making it strong. Who's have thought a cardboard shelf would hold that much weight? :-)

[CLTuna]

I use the rounded end of a window screen spline tool and a straight edge to make fold "grooves" then add a bit of wood glue to stiffen once clamped in place.

[bliptrip]

Thanks for the useful tips. I was wondering if wood glue would even be better for something like this, although it doesn't set as fast. And maybe paraffin wax for waterproofing (as long as not used in area with high temps).

[AndrewA167]

Great way to recycle that stuff! How have you found the glue to hold up (mainly the "sheering" weight between the shelves and "leg rails")?

My fear would be that standard hot glue would separate from the paper...

The more industrial high-temp hot-glue might be a better thing; there is also special "hot glue" systems made for cardboard box manufacturing that definitely is meant to "take the weight" so to speak - but that might not be very cost effective (I think ULine carries such things).

If you were willing to wait some time - using something other than hot glue would be possible - E6000 adhesive, or maybe a polyurethane adhesive (gorrilla glue or similar) would be very effective...