Thought I'd take a stab at Howard's castle-tunnel project, making a few changes along the way. Haven't gotten too far, but beginning with the tunnel underpinnings:Lengthened the tunnel by 4-5 inches, reduced the pitch of the portals, and modified the arch a bit. I also made it slightly narrower, but a half-inch taller. I plan to use a bit of foam-board in place of wood to cut down on weight. More to follow.

winced36...

looking good for sure!...it all starts with a strong foundation...and you've certainly got one there...keep posting the pictures!...

howard...

Thanks for the encouragement, Howard, and thanks again for providing the project details.

I got the liner fitted over the weekend, but it was a bear:I was going to use cereal box cardboard for the liner, but couldn't find any that was long enough (possibly the result of me lengthening the tunnel by 4-5 inches). Reverting to corrugated, I had difficulty getting it to take a graceful arch form. I used an old shipping tube as a sort of form, but the cardboard had a tendency to bend incrementally rather than in a nice curve. The ends look okay because they are glued to the form of the portals, but at the middle the ceiling is a bit notchy.

The other problem was I neglected to take into consideration the tilt at the top of each portal caused by the pitch they were cut on. When I glued in the liner at one end, a noticeable down-hill angle resulted. I had to force-fit the opposite end using a quite a bit of Titebond and a half-dozed C-clamps. The combination of the force-fit and the poor arching at the center resulted in a very slight hump. Twenty-four hours to dry, then I trimmed off the excess corrugated.

Presumably, the next step is to manufacture a couple of supports that sit over and atop the liner. These will hold the base of the structure that goes above. I'm thinking of using one-inch foam for these, but if that isn't strong enough, I'll use some scraps of one-by lumber. I've left the liner unattached to the side rails in case I need to do a bit of fiddling to get things to fit. When this bit is done, I'll glue the liner to the side rails.

Not to get too far ahead of myself, but I do have one question. How do you guys separate corrugated to get at the rippled bit that you used for the building's roof and some of the trim? Or is that material from somewhere else?

Paul

paul...

wouldn't fret too much about the interior of the tunnel...no one will ever see it...

the corrugated cardboard that shows the "ripples" or "flutes" is called SINGLE FACE CARDBOARD...it was widely used in packing and shipping before bubble wrap...note...i usually laminate the single face to a layer of cereal box for strength and rigidity...

try the scrap booking supply department of local craft store for the very small ripples...about 8 per inch...

i know the larger ripple stuff is sold on line by ULINE...it comes in either 4 or 5 ripples per inch...the issue with ULINE is the quantity you might have to purchase...

note...i have been lucky several times to find single face on displays of beer and soft drinks at local grocery stores...was able to get some when the displays were being torn down...

contact me off the forum...i may be able to help you directly...

howard...

sawdust 43 at bell south dot net

Thanks, Howard; I'll flip you a note. I'll hit the local craft stores and swing by Shipping Station when I get the chance. I've got time, as holiday prep is going to start intervening in my progress.

A bit more progress. I cut a couple of supports that I was going to fit snug to the tunnel liner and then build up, but then I decided I need more height for the plateau anyway, so I just glued them in and ran 2-1/2 inch screws up from the bottom. Unless I'm missing something, I think this should work.Since I lengthened the tunnel, I cut the base of the plateau a little bit bigger to try and keep the scale true to Howard's version, and I may flip it so it's position is opposite. I'll have to make that decision before I cut the base pieces for the tunnel.

More fun than I've had in awhile. Tomorrow's outdoor light day, later a trip to the cemetery to decorate for the parents, than off to choose-n-cut a tree this weekend. I may be in traction by Sunday...

We continue. Cut the base(s) from a scrap sheet of 1/4-inch exterior-grade plywood, then affixed them with a bit of Titebond and a half-dozen cabinet screws.At this point, it's probably strong enough to stand on, lol.

Gave the tunnel liner a quick spray of satin black, and sanded the portals flush.

Next up, the "plateau". I have cut one, but I'm not sure it's large enough to keep the scale similar to Howard's. Might think on it for a few days.

Paul II

Paul ll...

"Overbuilt is Built Right"...looking forward to pictures of the next steps...and by the way...did you find your single face cardboard?...

Howard...

Not yet, Howard...haven't had a chance what with Christmas prep duties this weekend (stringing outdoor lights, wreaths for the cemetery, and the choose-n-cut excursion for a tree). Sometime this week I'll hit Michael's and a couple of my shipping haunts...hopefully they'll have some in inventory. I found some on eBay for ~ $15.00 for an 18" wide roll, 20 feet long...does that seem reasonable? It's not pressing quite yet as I'm still a ways off from building the castle bit.

I have a packing tube I was thinking of using for the round turret, but that's some heavy stuff. A paper-towel roll seems a bit light. What did you use for your round keep?

Paul ll...
I used a paper towel tube for round keep...that's a lot of single face cardboard...I've never bought any of the roll stuff...I was lucky enough to salvage some single face from a grocery story beverage display...either beer or soft drink...
Howard...

Howard,

I'll use what I need and send the rest to you for a lifetime supply

Okay, I'll save a couple paper towel rolls, although they might be small since I upscaled it a bit. We'll have to see.

Thanks.

Paul II