Introduction: Reusable Litter Tray for PetSafe ScoopFree

I really like my PetSafe ScoopFree litter box, because scooping litter & the odor became a contentious issue at home. I don't like that it uses electricity, though. It uses crystal litter & rakes away turds, storing them with limited odor. The annoying thing is that they sell either disposable cardboard trays (wasteful) or very expensive reusable trays ($50!). I decided to make my own reusable tray. Here's how!


  • Coroplast (at least 18' x 25.5")
  • T-square
  • Pen
  • Utility knife
  • Duct tape

Step 1: Step 1: Get a Sheet of Coroplast

I found this sheet of 36"x72" coroplast (corrugated plastic) along the back wall of Home Depot. It's like the material used in lawn signs. It resembles corrugated cardboard, but, plastic.

Step 2: Step 2: Draw Out Lines on Coroplast

  1. Use your T-square to cut out a rectangle 18" wide x 25.5" long. (If you buy a 36" wide sheet, you can get two in side-by-side).
  2. Trace lines the sides of the box, 1 7/8" (1.875") from each edges of the rectangle you cut.
  3. Coroplast is 1/8" (0.13") thick. When folded, you want the shorter sides to cover the thickness of the longer sides. That's why the shorter sides extend out 1/8" in both directions.

Step 3: Step 3: Score the Inside Edges

  • Using your knife, score partially through the coroplast along the edges of the box you traced. You want to get through the ridges so it folds, but not through the other side

Step 4: Step 4: Duct Tape Together the Box

  • Fold up the sides of the box, and duct tape each side together.
  • It might help to put something that has a right angle, like another box!, while you're taping
  • You may want to tape thoroughly. However, an advantage of this box is that for cleaning, you could easily un-tape it and fold it flat for wiping clean!

Step 5: Step 5: Add a Bar to Hold the Turds

  • Measure & cut another strip of coroplast, 18" long and 3/4" wide.
  • Score and bend it to fit inside the end of the box.
  • Secure it to the side with duct tape rolls

Step 6: Step 6: Add Odor Trapping Bar

  • Cut another piece of coroplast, 13 1/4" long and 1.5" wide
  • Secure that to the inside of the purple hood, to help trap the odors.
  • You may want to take out the metal bracket from the cardboard litter tray to re-purpose it for securing this