I was thumbing through one of my RVing magazines a couple of years ago.  They were showing a collapsable windscreen for small tabletop grills.  It was made of aluminum and retailed for more than $50.  I took these steps to "build one cheaper" (my family teases me because I am always trying to build one cheaper).

Step 1:

I measured the place in my coach where I would store the windscreen.  I found a place that was 25" deep by 14" high.

Step 2:

I went to an appliance store and found a large corrugated cardbox that measured 25" wide (it was a dishwasher box).  They gave me the box.

Step 3:

I cut off the top 14" of the box.  Next I measured 14" in both directions from the 25" dimension.  And I cut along these lines.  Next I cut two of these corners.  This will form a gigantic T if you lay it flat... the top of the T will be 14 + 25 + 14 inches wide ... and it will be 14 + 14 inches tall. You can see the shape in step 6 below

Step 4:

The next step is prepare the screen to be more durable.  I sprayed all the surfaces with white spray enamel ... about 3 coats. (I learned this trick in my tent camping days ... varnishing or painting cardboard extends it life dramatically)

Step 5:

I thought the inside should reflect heat and be easy to wipe off.  I sprayed one side of the carton with 3M Spray adhesive and attached ordinary Reynolds Wrap to that side.  I used aluminum polymer tape (shiny duct tape) to bind the seams and the edges

Step 6:

I installed 6 grommets as shown in the photo ... notice there are also two holes in the inner corners of the wings that do not require grommets

 

Step 7:

I cut two 12" pieces of plastic clothesline and looped around through the grommets on the corners of the "bottom" (a recycled shoe string would work, too)

Finished Product

This picture shows the windscreen when it is fastened "open" ready for use.

 

This picture shows the windscren "folded" for storage

It is probably about 3/4" thick when folded (and 25" x 14").  The wings fold inside of the bottom and the same ties are used to keep it closed by threading through the grommets in the back (and the holes in the wings)

I have used the windscreen for over two years ... these pictures were taken after two years of use.

Materials used:

Corrugated cardboard box

3M spray adhesive

White spray paint

Reynolds Aluminum wrap

Aluminum polymer tape  (Shiny Duct Tape)

6 grommets

Tools used:

Utility knife

Hammer and grommet setting tool

 

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