Use custom cut plastic corrugated board to provide added support to the bag.
STEP BY STEP
1. Buy Plastic Corrugated Board from Home Depot or Lowe’s. Since I’m doing 4 bags, I bought a full sheet, which is 36×72. You will most likely only need 1 sheet, so just buy the 24×36 piece. You will find this in the front door section.
2. Cut a rectangle 15″ High x 28 1/4″ Wide
3. Along the bottom edge of the wide side, measure in 8 1/4″ from both edges and make a mark.You should have 11 3/4″ between the marks for the center section now.
4. Measure up the Height 10 1/2″ and the same 8 1/4″ in and make a mark.
5. draw a line between these two marks. You should have two vertical lines running parallel to the air channels in the board. They should be 11 3/4″ +- apart the whole length.
6. Cut on the lines you just made. A razor blade would be best if you have a safe flat cutting surface to score on. You can use scissors like I did, but the open close action might cause some snags in the plast. Trim these to make the cut as smooth to the touch as possible
7. Now that you have your two cuts, you also have your guides for your fold lines. You want to fold in both sides invidually so they lay flat against the middle section (or close to anyhow) to break in the bends. MAKE SURE the bend are on the outer edge of the cuts and not the inner edge. This will make the side panels more flush to the side of the bag.
8. This step is simply a set of coordinates. the first is the distance measured UP from the bottom edge, the second is the distance from the outer edges. These coordinates will plot a curved line to cut on.
6 1/2″ x 1/4″
8″ x 1/2″
9 1/2″ x 3/4″
10 1/2″ x 1″
11 1/2″ x 1 1/2″
12 1/8″ x 2″
13 1/8″ x 3″
14″ x 4″
14 1/2″ x 5″
15″ x 6″
9. You should now have 10 plotted points. Carefully draw a nice smooth line starting in the bottom corners and connecting the dots. Cut along this line careful not to create burrs that will snag the inside of the bag.
10. Follow the steps on the video.
11. One other step that might help some of you is during step 6, instead of just cutting a single line you could cut out a full channel or two towards the center. This would make the center section slide in a little easier than in the video, but it might shift from side to side…not sure, just a suggestion.
