Supplies
Industrial wire spool (diameter = 32" , height = 27")
4 half sheets of plywood 1/2" thick
3/4" corner braces
5mm x 1 3/4" straight rod long pins
1 3/4" Screws
5mm x 1 3/4" straight rod long pins
1 3/4" Screws
1/8th inch 3x3 rubber floor mat
12" lazy susan bearing
String
Adhesive Spray
Sand Paper
Stain
String
Adhesive Spray
Sand Paper
Stain
Drill
Drill press (recommended)
Circular Saw
Table Saw
Jig Saw
Drill press (recommended)
Circular Saw
Table Saw
Jig Saw
What to do:
First off I would like to say I had a lot of help pulling off this project my boyfriend and his dad played a huge part in getting this done.
- Cut four dividers 24"x10" (or what ever the dimensions of your spool are) out of the plywood using a table saw.
- Drill 3/8" holes 1 inch apart down the length of each side of your dividers. I suggest using a drill press but even this way it is a tedious process. This is where your long rod pins will be inserted to hold the shelf .
- Place the four dividers even spaced around the table and screw into place through the top and the bottom of the spool.
- Using a 1/2 sheet of plywood start by marking the center draw lines from corner to corner to find the center. Put a screw in the center of the 'X' use a piece of string tie it around the screw and a pencil on the other end at the length of the diameter of the spool (Circle 1 in figure below). Repeat this to draw circle 2 by measuring the depth into the center of the spool (arrow in picture below) (this would also be the width of your uprights you cut previously) and subtract this from the diameter twice to get the length of the string.
- Cut out all four wedges using a jig saw to cut the curves and a circular saw to cut the straight sides. Then use one as an outline to cut out the remaining number of shelves from the final sheet of plywood (I had a total of 9 shelves but I only use 8). Once you have the shelves, cut 1/4" from each end to take into account the size of your dividers (or 1/2" from one side).
- Drill 3/8" holes 1 inch apart down the length of each side of your dividers. I suggest using a drill press but even this way it is a tedious process. This is where your long rod pins will be inserted to hold the shelf .
Note: For spacing of the holes use whatever you plan to put on the shelf as spacing. We had to go back in and add new holes to make the shelves fit to hold three rows of DVDs.
- Place the four dividers even spaced around the table and screw into place through the top and the bottom of the spool.
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- Using a 1/2 sheet of plywood start by marking the center draw lines from corner to corner to find the center. Put a screw in the center of the 'X' use a piece of string tie it around the screw and a pencil on the other end at the length of the diameter of the spool (Circle 1 in figure below). Repeat this to draw circle 2 by measuring the depth into the center of the spool (arrow in picture below) (this would also be the width of your uprights you cut previously) and subtract this from the diameter twice to get the length of the string.
- Cut out a square that is 2'x2' out of plywood. Mark the center similarly to the figure above. Align the spinner with the center and screw to the plywood base. Drill a hole through the spinner and plywood base that will align with the screw holes you will be using to attach to the spool. Align the spinner/base on the center of the bottom of the spool and use the hole you drilled to screw to the spool (you will have to rotate the hole as you go to get to all of the screw holes).
- Spray the plywood base and rubber with adhesive and let it dry. Then coat them both again and place the rubber on the plywood. Allow to dry then cut rubber to match plywood with a razor blade or pair of scissors.
- Sand all rough edges and existing spool (I went sparingly on the spool as it had ink stamps that I wanted to keep. Stain with your chosen color.
- Place the long rod pins into the drilled holes on the uprights. Place the shelf on the rods and then use a corner bracket at the back of the shelf and screw it to the bottom of the shelf and the center of the spool. (This keeps the shelves in place and prevents them from flipping out.)
- Spray the plywood base and rubber with adhesive and let it dry. Then coat them both again and place the rubber on the plywood. Allow to dry then cut rubber to match plywood with a razor blade or pair of scissors.
- Sand all rough edges and existing spool (I went sparingly on the spool as it had ink stamps that I wanted to keep. Stain with your chosen color.
- Place the long rod pins into the drilled holes on the uprights. Place the shelf on the rods and then use a corner bracket at the back of the shelf and screw it to the bottom of the shelf and the center of the spool. (This keeps the shelves in place and prevents them from flipping out.)
This is where I got my original idea, it was a much smaller spool and only had one shelf. The spool I got was much larger so my thinking got much larger with that.
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