Anyway I have a sweet old grill I use for camping. It was bought many years ago used a few times and stored (forgotten) in the original box until recently when I pulled it down from the rafters and started using it again. The problem is carrying a dirty grill inside the truck. Trash bags not so good. I wanted light and strong and sorta weather resistant. Something that packed easy.
I took the original box and opened it up and taped the top flaps to extend the sides. Made a matching top. and covered it with TBII and an old bed sheet inside and out.
The materials.
The box partially covered.
I worked in stages covering 1 direction inside and out then letting it dry and coating the other direction In + out.
Glue coating for second ply.
The lid
Extra stiffener for bottom. Coated both sides.
Test fit.
After gluing I covered the whole thing with a coat of diluted glue. The process really saturated the cardboard so I left this thing out in the sun to cook in various positions off and on for a couple of weeks to really cure. Then I used some water based exterior paint I had in the cabinet and gave it 2 coats inside and out. I also cured this in the sun for a couple of weeks. Then I added an old boat cover strap as a lid hold down and handle.
It's now been on a couple of 4x4 camping trips and seems like it will hold up fine over the long haul. I can fit charcoal and started for a couple of days inside with the grill. It is really just a very strong weather resistant cardboard box. Very similar to a fiber drum case now. Only thing I bought was some TBII. Mission accomplished! Not too shabby for a 20+ year old beat up card board box. My wife figures she could stand on it no problem at all.
I intend to use the same process to make some other cases and also some lift out trays with dividers for my action packer style boxes that carry my kitchen stuff.
