I had a "what if" thought when I found an old, heavy weight cardboard fabric header in one of my storage boxes. The cardboard was a good thickness for a journal cover. Since the header is folded to hold fabric samples, there's a front and back piece. I cut off 5.5" from one end. Then I cut along the crease separately the front and back cover pieces.
Instead of making a journal with signatures, I opted to cut strips of 100lb Bristol paper and make an accordion style journal. I cut a spine from cardboard then attached the covers and spine with decorative duct tape. The opposite edges of the covers were decorated with washi tape. The final size is 5.5" x 3.5" x 1".
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