Instruction Manual

ENC3254

Morgan Flinchum

HOW TO MAKE AND HANG AN ORIGINAL CORK BOARD

INTRODUCTION
This guide will help you to create an appealing, original cork board on which photos and memorabilia can be affixed. Your cork board will be made using mostly recycled or reclaimed materials in an easy and efficient manner. This is a basic, straightforward guide; however there is room for some creative divergence.

NECESSARY MATERIALS:
Workbench or table in a clear, well-ventilated work area A Sturdy Frame (from a second hand store or flea market) Heavy duty, Corrugated Cardboard (recycled from an old box) 150-450 Corks, depending on size of frame Safety Goggles Cordless Drill 2 Small Screws (shorter than the depth of the picture frame) Appropriate Drill Bit Liquid Nails Adhesive Caulk Gun Handscrew Clamps (optional) Hammer Picture Hook Wire 2 Small Picture Wire Loops 2 Picture Hooks Razor Knife or Equally Effective Pair of Scissors Thumb Tacks Personal Photographs and Lightweight Memoirs

Instruction Manual

ENC3254

Morgan Flinchum

IMPORTANT SAFETY INFO:

NOTE: When this symbol appears, stop and carefully read the warning or caution notice that follows. Comply completely with the stated safety requirements. Make sure to use a well-ventilated area for varnishing or staining the wood. The same applies while gluing the corks on with Liquid Nails Adhesive. The vapors emitted by the aforementioned can be potentially harmful if inhaled in excess. Let the cork board sit in a well-ventilated area while the product is drying. If cutting with a razor knife or scissors, do so slowly and mindfully. Secure them in a safe, out of the way place when not in use.

INSTRUCTIONS:
1. COLLECTING THE CORKS Visit local bars and restaurants and ask for as many corks as they can provide. Likely, you will need to visit several different establishments. Reusing these corks that would otherwise be trashed is a classic example of recycling which in turn helps keep the environment healthy, albeit to a small degree.

NOTE: This step could take anywhere between 2 6 weeks. Be kind and patient and your cork collection will grow more successfully.

NOTE: You may need to talk to establishment owners or bartenders well in advance in order for them to begin saving corks, as they are typically thrown out promptly.

Instruction Manual

ENC3254

Morgan Flinchum

TYPES OF CORKS: Not all corks are created equal!

Here is an assortment of the many different types of corks (photo, left).

http://en.wikipedia.org/wiki/File:Wine_Corks.jpg

Part of the allure of this original cork board is that it may contain an assortment of unique corks from all over the world. Most wine corks are about 1 inches long with a 0.8 inch diameter (4.5 cm. x 2 cm.). However, the sizes range from size miniatures to bulbous 1 in. (2.5 cm.) diameter champagne corks. Consequently, it is important to get an idea of how you want the corks to be arranged before permanently affixing them to the board (this will be discussed further in a later section). Corks can even be cut in half using a razor knife or good pair of scissors, for a better fit.

CAUTION: Use extreme care while handling a razor knife or sharp scissors. Work slowly and be mindful to prevent injury.

Instruction Manual

ENC3254

Morgan Flinchum

2. THE FRAME Obtain an inexpensive yet sturdy frame from a thrift store or flea market. o Pick one with character that appeals to your personal taste.

This is an example of a low-cost frame purchased from a thrift store (photo, left).

Now varnish or stain the frame to your liking. Follow the instructions on the can for applying the particular varnish or stain that you choose.

WARNING: Keep the varnish or stain away from your face. If it makes contact with your eyes or mouth it could cause serious harm. Wash hands thoroughly immediately after using these products. WARNING: Apply the varnish or stain in a well-ventilated area as inhalation of these chemical products is potentially harmful. Likewise, leave the frame to dry in a well-ventilated area after the varnish or stain is applied. WARNING: Avoid getting varnish or stain on your hands or clothes. It is extremely difficult to remove.

Instruction Manual

ENC3254

Morgan Flinchum

This is a finished cork board frame with a single coat of varnish (photo, left).

NOTE: Varnishing or staining the frame is optional. It will give it a more vintage quality. The coat will bring out, more noticeably, the faults and crevices present. Maybe the frame you picked out already has an element of antiquity; in that case varnishing or staining may not be necessary. NOTE: It is also possible to build a frame from scratch using four decent-sized pieces of old scrap or drift wood. This will require proper measurement techniques and some type of saw. WARNING: If you choose to make your own frame, and need to incorporate the use of a saw, use extreme caution and work slowly. All saws are dangerous and can inflict a serious wound if used improperly.

3. ATTACHING THE BACK Find a piece of corrugated cardboard roughly the size of the frame. o Try salvaging the cardboard from an old box. Make sure it is durable and not too damaged. The dimensions may not be of the correct size. If not, use a razor knife or sharp scissors to cut a piece to the desired size. CAUTION: Use extreme care while handling a razor knife or sharp scissors. Work slowly and mindfully to prevent injury.
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Instruction Manual

ENC3254

Morgan Flinchum

Put the frame face down on a workbench, table, or other flat surface. Connect the container of Liquid Nails to the caulk gun.

This is what the Liquid Nails container will look like after it has been installed correctly into the caulk gun (photo, left).

http://www.aidtopia.com/halloween/tombston es/index.html

Snip the end off of the Liquid Nails container using scissors or a razor knife.

CAUTION: Use extreme care while handling a razor blade or sharp scissors. Work slowly and mindfully to prevent injury.

Run a consistent bead of Liquid Nails around the back of the frame.

WARNING: Avoid getting Liquid Nails Adhesive on your hands or clothes. It is very difficult to remove. WARNING: Apply the Liquid Nails Adhesive in a well-ventilated area as inhalation of these chemical products is potentially harmful.

Place the correctly dimensioned piece of cardboard on top of the adhesive. Attach four or more handscrew clamps to each of the sides of the frame and cardboard.
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Instruction Manual

ENC3254

Morgan Flinchum

This is a typical handscrew clamp (photo, left).

http://www.popularmechanics.com/home/revi ews/4288700

NOTE: If clamps are unavailable to you, it may be just as effective to lay the board and frame fixture on a flat surface and place some weight on top of it. Do not use excessive weight, as little weight is necessary. Also, be sure to not crush the middle part of the cardboard with this weight. Leave the assembly in a dry, well-ventilated location for 24 hours. Retrieve the next day. You now have a surface to adhere corks to! NOTE: When corks are put on and secured, everything will pull together and add to the structural integrity.

4. AFFIXING THE CORKS Plan a pattern. This is the recommended pattern: a two-bytwo checkered arrangement (photo, left).

NOTE: There are an infinite amount of possible pattern choices. Thus, there is room for artistic deviation on this step.

Lay the corks out on the board in the desired pattern. NOTE: At this point you are just laying the corks out. Do not use an adhesive yet.
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Instruction Manual

ENC3254

Morgan Flinchum

NOTE: Make sure corks fit securely in the frame. There should be no empty space left. If your pattern does not allow for this, the use of different size corks should be employed. Using a limited number of larger, champagne corks always leaves room for creativity.

Shown is an example of the incorporation of champagne corks to fill in the gaps left when creating the pattern (photo, left).

Take the corks out, but remember the pattern layout. Squirt a moderate coating of Liquid Nails Adhesive onto the front side of the cardboard. o Make sure the coating is distributed through the entire surface of the cardboard. WARNING: Remember to apply the Liquid Nails Adhesive in a wellventilated area as inhalation of these chemical products is potentially harmful.

Place the corks individually, in the planned locations. Push firmly on each one and make sure that they fit snugly within the frame. Let the corkboard dry for at least 24 hours.

5. HANGING YOUR CORK BOARD Gather the picture hook wire, the 2 Small Picture Wire Loops, the 2 Picture Hooks, and the 2 small screws. Also have the cordless drill and hammer handy.

Instruction Manual

ENC3254

Morgan Flinchum

Small Picture Wire Loops, a Picture Hooks, and the cordless drill (photo, above).

Using the cordless drill, drill a pilot hole a third of the way down from the top on each side of the picture frame, on the backside.

WARNING: Wear safety goggles while operating the drill. Small wood fragments or particles can be flung at high speed when using such power tools. Special precaution should be taken to protect your eyes and vulnerable body parts. Secure each of the picture wire loops using the two small screws and the drill. Push the wire through each loop and twist it about itself until secure. o The wire should be taught just so, that when the board is hung on the wall the wire remains hidden behind it.

The attached picture wire loops with the wire affixed should look similar to this (photo, left).

Hammer the two picture hooks into the wall at a 45 degree downward angle o This angle, and the design of the hooks, will insure that the weight of the cork board will be adequately supported in its position on the wall.
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Instruction Manual

ENC3254

Morgan Flinchum

CAUTION: Take care when using the hammer. Stay alert and work with control to prevent injury. NOTE: Using two picture hooks, instead of one, is advantageous in that it provides more stability, twice the holding power, and makes it easier to level.

Hang your cork board on the wall.

6. PIN PHOTOS ON THE BOARD Select photos and memorabilia to put on your cork board using thumb tacks.

Enjoy your new cork board!

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Instruction Manual

ENC3254

Morgan Flinchum

Image Sources:

Stowe, R. (2008). Wine Corks [photograph]. Retrieved from http://en.wikipedia.org/wiki/File:Wine_Corks.jpg [Picture of a handscrew clamp]. (n.d.). [digital photograph]. Retrieved from http://www.popularmechanics.com/home/reviews/4288700 [Picture of Liquid Nails attached to a caulk gun]. (n.d.). [digital photograph]. Retrieved from http://www.aidtopia.com/halloween/tombstones/index.html

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