A cardboard shelf to fit a Benno Ikea cabinet with a pleasant appearance!
Step 1: Materials
corrugated cardboard, approximately 1/8" to 3/16" (free)
white posterboard (Dollar tree 50 cents)
fine pointed applicators (recommended)
xacto knife or CNC paper cutter
clamps (the more the merrier)
cutting and scoring patterns (attached)
Step 2: Cut and Glue the Cardboard Interior
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
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
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
Step 6: Make the Shelf 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
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!
Step 9: Parting Thought
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....