Box Projects: Cardboard Bed Tray
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HARDBOARD: Corrugation makes layered and compressed cardboard tough as nails—and light as a feather. These sturdy trays weigh in at less than 5 pounds each. -
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Trim the cardboard to uniform size. If you’re using old boxes, 12" x 17" will do. For sheets, 12" x 48" are preferable. Where possible, cut perpendicular to the corrugation.
Pour a cup of glue into the paint tray and apply in thin layers to one side of two sheets. Align and press together. Continue adding layers until you have a 1" thick block. Make two of these blocks.
Compress the blocks with phone books until dry (two to four hours). Wipe away excess glue so the cardboard doesn’t stick to the books.
When the stacks are dry, use the jigsaw to cut 36 2"-wide strips. Don’t let the blade wander. Next, trim the strips to make 12 each of three lengths: 17", 10", and 8".
The tray fits together as a sequence of U shapes. The 17" pieces form the top; the sides alternate 10" and 8" pieces. (See illustration.) To make the basic shape, lay one 17" piece horizontally face down. Then glue 8" and 10" pieces at either end to make an even U. Create subsequent layers the same way, but reversed, so the 10" and 8" pieces alternate. Continue until you’ve used all pieces.
Check the alignment on all sides to ensure evenness, then compress and hold in place with masking tape.
After two to four hours of drying time, remove the tape and smooth with 60- to 100grit sandpaper.
For more durability, add masonite to the ends. Trace two of the U shapes onto the wood, and tape in place. Remove tape and sand even when dry.
