I start by finding large pieces of corrugated material - primarily double and triplewall. I'm looking for post consumer materials that are clean, sturdy and not too dented or battered. It doesn't have to be perfect as I can work around a damaged section.
- There are the triplewall vegetable bins from the produce department.
- I look for big boxes - television boxes are usually made of doublewall but refrigerator boxes are just singlewall. Singlewall is good for some things but is not sturdy enough for the structural base.
- Big box warehouse stores receive and display goods by the pallet. Between the layers on the pallet, are sheets of heavy paper (sometimes textured) or singlewall/doublewall corrugated. I collect the doublewall corrugated to use for building the structural part my work, but I also collect singlewall and textured paper for many other uses.
Tools: I use a selection of simple tools
- On my work table I have a large, self-healing cutting mat. This protects the table top surface from the wear and tear from my cutting blades and it helps keep my cutting blade sharper, longer.
- For a cutting blade, I prefer a sturdy utility knife with a retractable blade.
- A metal ruler is good for measuring and also serves as a guide for cutting straight lines.
- I also use 45 degree and 30-60 triangles to measure and cut angles. Plus a t-square or l-square for cutting 90 degree corners.
- Scissors, tweezers and a selection of glues are also needed. My primary glue is a plain, white craft glue.
To make a desk clock frame, I start with triplewall, cut pieces that are 3" wide and an inch or two longer than needed. I glue these pieces together to form the shape and size for the clock I am planning to build. Once the glue has dried, I cut off the excess material. I add triangular pieces inside the corners to reinforce the frame and provide support for the clock face.
To make a hexagon wall clock, I would use doublewall and draw out the shape - either to the desired size or to fit within the dimensions of the piece of corrugated I plan to use. Once the shape has been cut, I score and fold the walls of the clock so I can glue it together. I add rectangles of triplewall along the inside of each side as reinforcement and to support the clock face.
I generally use doublewall for the clock face.
The frame construction process is similar for everything I create with corrugated.