Recycled Sign Box

This is a storage box that uses old election or advertising signs made of corrugated plastic (coroplast). Each box uses one 18x24 inch sign (457mm x 609mm x 4mm) and two of the metal sign brackets. The sign brackets are cut down into 18 inch sections and used as inserts to keep the sides and bottom rigid. A 300 mm print bed is required. 

The boxes are very sturdy due to the metal reinforcement. I have tested them with weights and I can lift 55 pounds by the handles without damage to the box.

Assembly: 

1. Print two side walls and 14 dowel pins. 

2. Cut down the sign brackets into four 18 inch (457mm) pieces. I used a hacksaw to cut the metal and a file to deburr.

3. Measure in 6.5 inches (165mm) from each side. Bend the sign 90 degrees so it can be inserted into the printed side wall piece. It is best to do this over the edge of a table. Do this for both sides and insert it into the side wall.

4. Insert the metal rods you prepared. Put one in each end of the sign to reinforce the long side walls, and two on the bottom. Place them where the dowel pins will not interfere. You may need a mallet to insert the rods fully.

5. Use an ice pick or something similar to poke holes where each dowel pin needs to be inserted. Ensure the sign is pushed tightly into the side wall first. Insert the dowel pins, one side is pointed to assist with insertion. Push until the pin is flush with the surface. They should be tight. You may need a mallet to help.

6. Do the same on the second side wall. You should now have a fully assembled storage box.