My grandfather grew up on the wrong side of the tracks, and had to make do with just the things that he had. One of the skills that he learned was building a better cardboard box. He would fit and glue boxes together, and add wooden handles to make nearly indestructible cardboard tote and storage boxes. I have some of his old boxes that are 53+ years old, and they are still strong. My father never had the knack for it, but my uncle did! He would use the cardboard like plywood and fill edges with glue to add strength. He also built specialized tote boxes for things like his Ham radio gear, and RC aircraft supplies. If you have lots of cardboard available, then this is a good way to recycle it.
Grain is Strength!
The grain of cardboard is just like the grain of wood. The side with the small holes is the end grain. Almost all boxes are built with the grain running vertical, and crossed grains on the top and bottom. Crossing the grains adds strength to the top and bottom of the box. This is the same way that plywood works. So in building up boxes, we cross the grains to add strength.
Building up a Box
Here is the basic box-building procedure: Start with an existing cardboard box that is larger than the object that you want to place into it. You will lose anywhere from a ¼” to 3/8” or more, depending on the number of plies of cardboard that you use. I normally cut the top flaps off of the box. Start by gluing the inside flaps to the outside flaps with a waterproof wood glue.
Rectangular boxes will need a filler in the “step-down” section in the bottom-center. Match the filler grain with the flaps, and glue it down. Next cut a panel that fits the entire bottom with the grain opposite of the inner flaps, and glue it down. I normally go with three plies for the bottom, but more could be added if needed. Next, cut two panels to fit the sides with the grain running opposite and glue the three edges and face of the panels to the box.
Now, cut another two panels for the ends, and glue them into place. Repeat again with the grain running opposite. It helps to use weights to hold the cardboard down while the glue cures. Next, measure the height required plus 3/8” for a lid, and trim the sides. This will leave a square edge all the way around. Fill the edge with glue and let it dry. You may have to go over the edges multiple times, since some of the end grain will suck the glue into the corrugations.Continue reading“Custom Cardboard Box Making, by Captain Nemo”
