Build Instructions

Collapse

• 1

  Step 1

  Print pages

  For lay-flat style binding, you're going to print single-sided two-up. Because I don't actually have an 11x17 printer, I had a print shop do this for me.

  Make sure the first sheet of paper only has a page on the right-hand side. This will be your title page, and the left side will be used for gluing to the cover later.

  Similarly, the last sheet of paper you use should (in most cases) only have content on the left side, with the right side being used for gluing to the cover. I cheated on this point because the last page of content is only occasionally useful for me.
  

• 2

  Step 2

  Construct jig.

  In the pictures, you'll notice my jig is a two-part system; a three-sided tray for holding pages, and a flat sheet that presses on them, all wrapped in wax paper. Note that the tray only fits the pages once the paper is folded in half. We need the jig for folding, so just use the full stack of printed pages for measuring/test fitting for now.

  Use a metal brake or a bandsaw to cut the sheet metal to size. I prefer the metal brake because it's a very clean approach. Make sure you have 3/4"-1" of space on each side of the tray for folding the walls. Also make sure that all cuts are square with the machined edges and each other. Set aside the piece that's going to be the flat sheet, we'll get back to it later.

  Score lines where you'll be folding the sheet metal to make your tray walls. Make sure the folds are going to be square with the machined sides, the cut edges, and each other.
  

  Because I'm working with 26 gauge metal, tin snips worked just fine for removing the two corners of the tray that will prevent folding.

  Lastly, I used a metal folder to fold three sides of the tray to walls. If all your measurements came out right, your pages should fit in the tray, and they should have a snug fit in the tray. The sheet metal press should also fit in the tray, on top of the pages, with a snug fit.
  

• 3

  Step 3

  Use jig tray to fold the sheets of paper

  Using the tray to make sure that you have the corners and edges lined up, fold each sheet of ledger paper in half, one at a time. The printed content should be on the inside of the fold, and you should have one "printed page on each side of the fold. One of the pictures should have a final result of this folding visible.
  

View all 9 instructions