Carry That Weight: Cardboard Backpack
Posted by ReadyMade
Photos Claudia Goetzelmann, Project by Zachary Warwasleft
Perfect for bookworms or bloggers on the move, this backpack—complete with a handy locking mechanism—is made with one piece of folded cardboard, a few strips of wood, and a fabric strap.
Skill Level
Moderate
Active Time
Half a day
Cost
$
- Sheet of cardboard
- 2 5 1/2" x 12" pieces of 3⁄4" plywood
- 3/8" x 3/4" wood strip cut to the following lengths: 4 pc 11"
- 2 pc 4 1/2"
- 1 pc 16 1⁄4"
- 1 pc 3 1⁄2"
- 60" fabric strap
- 14 1 1⁄4" wood screws
- 2 1 1⁄2" wood screws
- 2 1⁄4" wood screws
- Double-sided tape
Materials
- Measuring tape
- Utility knife
- Metal ruler
- Pencil
- Bone folder (optional)
- Power drill and bits
Tools
Measure and mark a 16" x 44 1⁄2" rectangle on the cardboard, with the corrugation parallel to the 16" side. Using a utility knife and metal ruler, cut out the rectangle.
Lay it down with the long side toward you. Measure and mark vertical lines 12", 17 1⁄2", and 29 1⁄2" in from the left edge.
Use a bone folder (or the side of a sturdy table) to fold the cardboard along your lines.
Stand a piece of plywood on its narrow edge, long side down, and place it in front of the bottom Warwasleft edge of the cardboard rectangle. Place the 12" cardboard segment on the plywood, flush with the edge. Position one of the 11" wood strips over the cardboard, 1⁄2" in from the ends of the plywood, and secure it by putting in the center 1 1⁄4" wood screw. Next, drill in the right-hand screw. Do not install the screw nearest to the end of the cardboard; it will be added later
Turn the plywood piece onto its short side, making sure the cardboard is snug and flush on this edge. Center the 4 1⁄2" wood strip on top of the cardboard, 1⁄2" in from the ends of the plywood, and screw it in.
Flip the plywood once more and attach the 11" wood strip as in step 5, except this time using all three screws. Leave the right and left screws slightly loose (they will be tightened after the strap is in place).
Flip the unit over, and attach the second plywood piece the same way you did the first, but instead of leaving out the top screw on the first 11" wood strip, omit the middle screw.
From the top edge of the backpack you can now measure and mark off where you will be folding the lid: at 5 1⁄2" and 9 1⁄2". Score and fold your lines
Fold the lid down over the backpack. On each side of the lid, mark where it hits the 11" wood strip. Cut a 3⁄4" strip from there to the end of the lid on each side. This allows the lid to clear the wood strips and close properly.
Install the angled crossbeam: Using 1 1⁄2" wood screws, attach the 16 1⁄4" wood strip to the top and middle holes you left empty in steps 5 and 8.
Slide the lid of the backpack under the angled crossbeam. Mark the angle of the crossbeam by lightly drawing a 2" line along the bottom of the beam in the center of the lid.
Use double-sided tape to affix the 3 1⁄2" wood strip to the lid such that its top aligns with the mark. From the inside of the lid, use the 1⁄4" wood screws to attach the wood strip. You may want to use a scrap piece of cardboard on the inside of the lid to add an extra layer before drilling in the 1⁄4" wood screws.
To attach the strap, set the backpack on its feet with the closed lid facing away from you. Starting at the upper-left corner, wrap the strap around the loosened wood strip one and a half times. Bring the end of the strap over and then under the top of the right-hand wood strip. Feed it through, leaving enough slack for a comfortable shoulder strap. Bring the strap’s end to the lower-left corner of the backpack. Remove the bottom screw and slide the strap underneath the wood so that it rests beneath the middle and bottom screws. Reattach the screw. Pull the strap across and wrap it around the bottom of the right-hand wood strip until the amount of slack is equal to that of the other strap. With the screws still not fully secure, test the fit of the backpack. Once the straps fit comfortably, tighten the screws.
Drop in a bubblewrapped laptop to complete the look.
