My original I'ble has been lost so I try to gather my thoughts back to make it short but efficient:
What you will need:
- cardboard cuttings
- 2 sheets of good standing cardboard
- glue (i use White or wood glue)
Let's build it
- Gather all cardboard cuttings you may have
- Glue all cutting on one of the sheets to make layers one on top of each other
- Once you have reach the appropriate thickness or once you run out of cuttings, glue the second sheet on the top
- Let's cure under some weight
- Take you jigsaw and cut your assembly to desired dimensions
- You're done!
- to obtain a good finish in your final object, use an appropriate blade
- if you want smooth sides, fill the corrugations with gap filler and sand lightly
- to mask little dents or imperfections you can glue colored light paper or even newspapers paper
- paint only suffers a perfect surface
- cardboard has 2 faces, one smoother than the other so take care to face this one outside. Often this is the one with logos and advertising.
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Let me know if you want more details!