so where to start, well, I was fumbling around in the electricians junk box in the workshop, and I came across a an old four pin electrical plug, its a 440volt type that we havnt used on our welders for a decade or more, we moved to 3 pins, years ago, but what struck me was how uniform the ribs were across the part you grip and twist into the socket, so I rummaged a bit more and found two more, I asked the sparky if he wanted them, no was his delightful answer, so off I went to measure and study them, and the upshot of this was that with a bit of work with a table saw I could make a pair of rollers, 2 inch in diameter and just less than 2 inches in length, and when placed opposite each other the ribs on the drums interlocked perfectly, the ribs when scaled down to 1/76, were to within a few microns of 3 inch ridge to ridge, or a 1/87 4inches rib to rib, so now I just had to mount them on something and roll some aluminium kitchen foil between them and I would have scale corrugated sheet!
first I mounted them is a bit of meccano to see how they ran together, and fed a piece of foil between them, it was good, but it stuck to the rollers, either top or bottom, and it was extremely difficult not to damage it, and getting it straight in the rollers was another problem, so off to the kitchen, a cup of tea and tube of ritz crackers, (always good to contemplate puzzles with tea and biscuits), so I decided to stick the foil to a piece of paper from the printer, I decided to use spray adhesive because its not water based so it wouldnt expand or be absorbed by the paper, I laid the kitchen foil shiny side up on a glass plate and then rolled it flat with a roller I made from an old printer feed roller, a bit of bar, and the handle off a broken paint roller, then sprayed the sheet of paper and placed one edge on the foil, then using the roller rolled it down onto the foil so there were no air bubbles in it, then I let it dry for a few minutes then cut it into strips as wide as the rollers of the plugs, and yes this worked better, it didnt stick to either roller, but it was hard to keep the right pressure and equal pressure the whole time.
So out came the box of meccano I bought off fleebay last year, and I made a frame and mounted the rollers in it, ran perfectly by hand, but it still wasnt even so I added a few springs to pull the top roller down onto the top of the bottom roller, now I could feed the strip and roll the top roller with my hand, and it worked, except that as before it was hard to keep it 90* to the rollers, so I had to make a paper guide, so a bit of styrene from an old for sale sign made a perfect feed guide and a collection plate.
Ok, it worked but it was very hard on my hand to drive the top roller, so out came the useful box, and I found the perfect drive system for it, a couple of years ago I was given a paper shredder to fix, but it was beyond repair, the paper cutters were just worn out, but the motor and gearbox worked just fine, 12volts as well. So with a bit more meccano and a bit of modifications I made a very powerful feed to the bottom roller, and fitted it to a piece of 12 x 8 plywood, then rebuilt the roller setup to use the gearbox output, now to test it!
It works exactly as it should, in fact it works better than I thought it would, well if you have stuck with me so far you deserve a few pictures for your patience, so here they are with a few comments.
this is the foil, 4 pin plug and spray adhesive I used to make the foil
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copyright © brit-in-bama 2018
, these were cut on my old regular guillotine, no deformation, or twisting. good thin bladed sharp scissors also work, or a sharp new blade in a chopper. 
