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carousel
Spin the entire carousel to access each of its six toolholding wings ...

A ton of storage in a tidy space

tool

... and rotate each wing to access both of its sides and the center column.

We packed all these tools and bits135 pieces totalinto an instant-access storage unit that takes up just 2x2' of wall space. Think of how it will help organize your shop!
DP-00256
Copyright Meredith Corporation 2003

Page 1 of 7

This handy shop helper is the brainchild of reader Jim Maw of Kleinburg, Ontario. His ingenious design earned the prize for Best Storage Solution or Organizer for Power Tool Accessories in our Great American Workshops Contest. We liked Jims organizer so much that we obtained the design rights from him, and then built one ourselves so that we can present the plans here.

Start with the carousel To make the top (A) and bottom (B), stick together two 1618" pieces of plywood with double-faced tape. Mark the top one A and the bottom one B. Referring to Drawing 1, lay out the hexagonal shape and location of the holes on the top (A). Bandsaw close to the line, and then sand the top and bottom to shape.

Drill the six " holes around the perimeter and the four " holes around the center through both parts. Countersink the center holes on the top surface of part A and the bottom surface of part B. Drill the 1" hole at the center. Make indexing marks across one edge of the joined parts for later reference. Separate the parts. Enlarge the perimeter holes in the bottom (B) to 764".

1 TOP AND BOTTOM

6" 4" 30
8"

18" " shank hole, countersunk on top of A and bottom of B

9" 1" hole

A, B
" 8" 4"

16"

9"

5"

Location of parts C " shank hole in parts A and B , redrill 1764" hole in part B

Page 2 of 7
TM

" shank hole, countersunk

#8 x 1" F.H. wood screw 1" hole

#8 x 1" R.H. wood screw #8 flat washer " shank hole

Indexing mark A

#8 flat washer " pilot hole 1" deep

7 64

C E

7 64

" pilot hole, centered

7" D 14" 15" C D C " R="

5" 4" 4" " hole " deep centered on part E E " dowel " long " flat washer
17 64

E #8 x 1" F.H. wood screw

2 CAROUSEL

" shank hole, countersunk with a 1764" pilot hole " deep 1" hole

B Indexing mark

" hole

#8 x 1" F.H. wood screw

" shank hole, countersunk on bottom face

Page 3 of 7
TM

Cut the core sides (C) to the size given on the Materials List. Glue and clamp the core together in the configuration shown on Drawing 2. Make sure the ends are flush. Drill pilot and countersunk shank holes where shown, and drive in the screws. Remove the clamps. To position the core between the top (A) and bottom (B), cut two 513" spacers. Make the spacers from poplar. [You can rip them later to 5" wide for the brackets (G).] Clamp the core between the top and bottom, positioning it as shown in Photo A. Using the countersunk shank holes in the top and bottom as guides, drill pilot holes into the ends of the core, and drive in the screws.

Indexing mark

Add rotating panels From " tempered hardboard, cut the six panels (D) to the size listed. Cut the panel cleats (E) to the size listed. Mark, bandsaw, and sand the " radii on their ends, where shown on Drawing 2. For the six upper cleats, drill 764" holes, centered on the length and the " thickness, where shown. For the six lower cleats, drill centered " holes " deep. Cut six " dowels " long and glue them in the holes in the lower cleats. Glue and clamp the cleats (E) to the panels (D), where shown. Set the panels aside.

1 2

With the indexing marks on the top (A) and bottom (B) facing upward, use spacers to position the core parallel to two sides. Measure in from the points, centering the core.

3 1

Attach an auxiliary extension to your miter gauge, clamp on a stopblock, and cut the notches in the back (F), making several passes.

Make the wall bracket Laminate two 522" boards for the back (F). With the glue dry, joint one edge and rip and crosscut it to size. Install a " dado blade in your tablesaw, and form the notches for the brackets (G), where dimensioned on Drawing 3, as shown in Photo B.
TM

Retrieve the boards used earlier for spacers, and cut the brackets (G) to the size listed. Mark the angled cuts, where dimensioned on Drawing 3. Bandsaw and sand to the lines. Cut the lower arm (H) and upper arm (I) to size. Using a Forstner bit, drill the 1" hole " deep in the lower arm, and the 1" hole in the upper arm,

2 3

where shown on Drawing 3. The holes are centered on the widths of parts H and I. Glue and clamp the brackets (G) to the back (F). Drill pilot and countersunk shank holes, and drive in the screws. Remove the clamps. In similar fashion, glue, clamp, and screw in place the lower arm (H) and upper arm (I).

Page 4 of 7

#8 x " F.H. wood screw

Finish and mount the carousel Sand all the parts to 220 grit, easing the 3" K edges with a sanding block. Apply the finish of your choice. We brushed on two coats of satin polyurethane, sanding lightly with 220-grit sandpaper between coats. 1" dowel 3 EXPLODED You also can prime and paint to match 17" long VIEW existing cabinetry. Cut two 33" hardboard blanks for the washers (J). Mark their centers, and draw 3"-diameter circles. Drill centered 1" holes, and bandsaw the washers #8 x 2" F.H. to shape. wood screw Cut the cover plate (K) to size. Drill countersunk shank holes at the four corners, where shown on Drawing 3. " shank hole, 1" hole With the finish dry, drill " holes countersunk through the wall-bracket back (F). 2" I Transfer these locations to the wall at a stud location. Drill pilot holes into the stud. 1" hole 764" pilot hole Now fasten the wall bracket J " deep with " lag screws 3" long. Cut a 17"-long piece of 1" 3" dowel. Place the carousel A E between the upper and lower 764" arms. Slide the washers (J) in pilot hole place between the carousel and 1" " lag screw the arms. Drop the dowel in E deep 3" long from the top, seating it in the C hole in the lower arm (H). D C D Center the cover plate (K) over the upper arms dowel hole. Using the shank holes in the 1" " flat cover plate as guides, drill pilot washer F holes, and drive in the screws. Arrange your tools on the panels and make the holdE ers. For the mounting methods 22" we used, see page 8. B With the holders now attached to the panels, slip 1" hole J washers over the bottom cleats 2" H " dowels, and tip the panels " " into place, seating the bottom 1" hole " deep cleat dowels in the holes in the carousels bottom (B). Slide a #8 x 1" F.H. #8 flat washer between the top wood screw G 5" cleat and the carousel top (A), where shown on Drawing 2. G 1" Secure the panels to the top (A) with flat washers and round764" pilot hole head screws. Attach the tools 3" 7 64" pilot hole " deep " deep and bits. " shank hole,
" shank hole, countersunk

1 2 3 4

6 7

#8 x 1" F.H. wood screw

countersunk
Page 5 of 7
TM

materials list
Part A top B bottom C core sides D panels E panel cleats F* back G brackets H lower arm I upper arm J* washers K cover plate T " " " " " 1" " " " " "

FINISHED SIZE

*Part initially cut oversize. See the instructions. W L Matl. Qty. Materials Key: BPbirch plywood, Ppoplar, Htem16" 18" BP 1 pered hardboard, LPlaminated poplar. 16" 18" BP 1 Supplies: #8" flathead wood screws (4), #81" flathead wood screws (32), #82" flathead wood screws (3), 4" 15" P 4 #81" roundhead wood screws(6), #8 flat washers 7" 14" H 6 (12), " flat washers (2), " lag screws 3" long (2), " " 7" P 12 dowel, 1" dowel. 5" 22" LP 1 Blades and bits: Stack dado set, 1" Forstner bit. 5" 5" 5" 3" 3" 13" 13" 15" diam. 3" P P P H H 2 1 1 2 1

Buying Guide
Tool Holders. Look for spring-clip tool holders and magnetic tool holders at your local hardware store, home center, or woodworking specialty store.

cutting diagram
J K

D A B D
x 24 x 48" Birch plywood E E

D D

D D

E C C

x 24 x 48" Hardboard E E I

x 5 x 96" Poplar

F
x 5 x 96" Poplar

Page 6 of 7
TM

Adding your tools and bits

C
ow many of the hundred-plus small items that clog the drawers in your shop can you fit onto your carousel? To plan the arrangement of your tools and bits, place the panels (D/E) on your workbench, and position the items, as shown in Photo C. You can store items on both sides of each panel, and also on the core. Note: For the panels to rotate, there must be clearance between each panel and the core. No bit, tool, or tool holder may protrude beyond an imaginary 8"-diameter cylinder, centered on the panel. Items stored on the core must not interfere with the panels rotation. For tools that can hang from a peg or pegs, mark the locations, and drill holes through the panels. Insert machine screws, and thread on nuts, as shown on Drawing 4. For drill bits and other tools that fit in round holes, measure the bit or tool center-to-center distances, and transfer these dimensions to blocks of wood. Drill holes slightly larger than the bit-shank or tool diameters. Clamp the holders to the panels. Drill pilot and countersunk shank holes from the opposite side, and drive in screws, where shown. (We didnt glue the holders in place, just in case we ever need to rearrange our layout.) If some of your tools have their own small case or holder, you may wish to mount it to a panel. To permanently attach the case, drill holes through it and the panel, and fasten with machine screws and nuts. For removable " machine screw attachment, adhere Velcro 1" long D tape to the case and panel. Other easy mounting methods are to use spring clips, as shown in Photo D, and magnetic toolholders, as " nut shown in Photo E. #8-32 x 1" machine screw
4 TOOL MOUNTING OPTIONS

Arrange the bits or tools you wish to store in the carousel on the panels. Leave enough clearance between items to allow for easy handling.

After fastening spring-clip tool holders to the panel with machine screws and nuts, snap the tools in place.

E
" nut Hole drilled for tool or bit. D

Produced by Marlen Kemmet Project Design: Jim Maw; Kevin Boyle Written by Jan Svec with Charles I. Hedlund Photographs: Marty Baldwin Graphic Design: Jamie Downing Illustrations: Roxanne LeMoine; Lorna Johnson Copyright Meredith Corporation 2003

To avoid having to make intricate holders for small or odd-shaped parts, mount a magnetic tool holder with a machine screw and nut.
TM

D #8 x 1" F.H. wood screw

The purchase of these plans does not transfer any copyright or other ownership interest in the plans, the design, or the finished project to the buyer. Buyer may neither reproduce the plans for sale nor offer for sale any copies of the finished project.

Page 7 of 7

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