Pro tip: I was taping my fort seams wrong until a guy at the Phoenix library build day showed me the 3 inch overlap | Cardboard Box Forts - The Community Guide
Pro tip: I was taping my fort seams wrong until a guy at the Phoenix library build day showed me the 3 inch overlap
Last month I went to a family fort event at the Burton Barr Library in Phoenix and watched a dad run tape down his seams twice, each strip overlapping the first by about 3 inches. I had been doing single strips and my roof kept popping open every time my kid leaned on it. Started doing the double strip thing on my own build and the corners finally hold. Anyone else got a tape trick that keeps big spans from sagging?
Cardboard choice matters as much as the tape for long spans. Single wall boxes are basically wet napkins once you go past a couple feet, so I grab moving boxes from the liquor store or wherever and double them up with the corrugated ribs running opposite ways. Then tape the whole thing like a cross, corner to corner both directions, and it stops the sag pretty well. Also score the cardboard along the fold line before you bend it, because a clean crease holds way better than a mushy one and your tape actually has something flat to stick to. The 3 inch overlap thing is real too, felt like I was wasting half a roll at first but the roof stopped caving in when my 6 year old climbed on it.