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I finally switched my TV stand mockup from double wall corrugated to single wall and the whole thing got 40% lighter
I built my first cardboard mockup of this mid century TV stand about three weeks ago using double wall corrugated I grabbed from a fridge box behind the appliance store on 5th. It looked fine on paper but when I picked it up to move it across the living room, the thing weighed almost 9 pounds and the legs just crushed inward at the joints. So I tore it apart and rebuilt the whole thing out of single wall, same dimensions, same 42 inch span, and it dropped to around 5 pounds and the legs held up great without any extra bracing. I think the real issue was that the double wall was so stiff it wouldn't flex with the load, so all the stress went straight to the corners and popped the glue. The single wall bends a little, which sounds bad, but it spreads the weight out and the whole frame stays square. I did keep one strip of double wall along the back edge just for rigidity and that seems to be the sweet spot. Has anyone else noticed that thicker cardboard actually makes mockups weaker at the joints, or did I just glue it wrong the first time?
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phoenix84512d ago
Went through the same thing building speaker cabs, thick board fights you at every corner and split the seams. Single wall plus a back strip is the right move.
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