Interlocking Tiles
I created an interlocking tile system inspired by Wylock's Armory, video #095, CardboardLOCK. You can cut dozens/hundreds of cardboard chits to size and that absolutely is an acceptable and free way to do it. You really don't need chipboard, although it would give you a consistent thickness you probably won't find in cardboard for around $8 on Amazon.
Looking at time/cost balance I personally decided that $8 was, in general, just fine with me to have an interlocking system, but I'd still be faced with cutting, gluing, and waiting for glue to dry so I looked for other means of getting it all done much more quickly without spending a lot more money. Enter dual-adhesive foam mounting squares.
Interlocking tiles have Bump Resistance +3
Tip: I've found that if you use a generic drawer liner sheet the cardboard tiles stick pretty well as an alternative/supplement.
Supplies
Notice: Although I try to update all of my links & prices at least once a month, Amazon sellers may change or remove the particular items or prices since the time they have been listed here. The items I have listed are the best that I have found at the time, but any item matching the general description should suffice for this project.
I've broken these down by size and then by part. In addition, I have added the keywords I used to find these items if you want to do your own searches or in the event that the seller has changed/removed the item listed below.
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Cardboard - $0-6 - for the bottom of the interlocking section and chits to hold them together
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Keywords: cardboard
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Box cutter $4 - I find the smaller ones to be perfect for the shortcuts needed
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Keywords: box cutter
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Forever in Time PD109 Square Dual-Adhesive Foam Mounts, 0.4in, 240Pc - $7/2pk - for tiles at least 2 squares wide, not counting walls
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Keywords: foam mounts
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Forever in Time PD108 3D Pop Dots Square Dual-Adhesive Foam Mount, 1/4-Inch, 528 Per Package - $4 - for tiles only 1 square wide, not counting walls
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Keywords: foam mounts
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Cut cardboard to the size of each tile you want to interlock
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Place a 0.4" mounting square a 1/2" inwards from each corner & one in the center of the tile
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Remove the backing from the top of mounting squares
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Line up and press the same-sized dungeon tile on top of the base (don't press too hard!)
Assembly
Tiles: 2x2
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Cut cardboard to the size of each tile you want to interlock
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Mark where the walls are (1/2" inwards) and if applicable, also 1" inwards from the edge. It's easiest to just draw straight across and no one will see the lines anyways.
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Place a 0.4" mounting square at each place where the outer edge meets the wall mark (edge against inside side of the mark)
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Center and place a 0.4" mounting square in the middle of each of the mark lines (centered 1" inwards from the edge) and if applicable, wherever if could use additional support
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Remove the backing from the top of mounting squares
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Line up and press the same-sized dungeon tile on top of the base (don't press too hard!)
Tiles: Bigger than 2x2
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Cut cardboard to the size of each tile you want to interlock
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Place 3 0.25" mounting squares along each short edge (You may only need 2, but I find 3 gives me a more comfortable sense of firmness)
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Remove the backing from the top of mounting squares
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Line up and press the 1x2 dungeon tile on top of the base (don't press too hard!)
Tiles: 1x2+
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Measure & draw a grid 1.25x1.5"* on cardboard. Each 1.25x1.5" rectangle will form a single chit
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Subdivide and draw the 1.5" sides into 3 0.5" sections
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Subdivide the 1.25" side in order as follows; 7/16", 3/8", and 7/16"
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Cut out each 1.25x1.5" chit section
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Cut all 4 corners of the chit where from where the subdivided sections are marked
*You'll need 1.25x2.5" chits for the 1x2 tiles since there's no place for a chit to anchor
Chits
How the chit and tile interlock