User:MikeBertrand6/ENES-100/Project 1/CDIO/Basic Pulley Tutorial

Materials

 * 1) Plywood
 * 2) One 1/2" dowel rod
 * 3) One 1/4" dowel rod
 * 4) 1/2" and 1/4" drill bits
 * 5) A 21/8" hole saw
 * 6) A regular saw
 * 7) A segment of string longer than the circumference of the circles
 * 8) A furniture nail
 * 9) Epoxy

Making the Circles
Start off by taking the plywood and the hole saw. Drill half way through one side of the wood with the hole saw. Then, flip the wood over and drill completely through until the circle pops out. Flipping the wood over prevents the wood from cracking.

Drilling the Center Hole
The hole saw has a small drill bit in the center, and it makes a small hole in the center of the circle. This can be used to guide the 1/2" drill bit used for the hole in the center. Take the 1/2" drill bit, put the tip in the hole made by the hole saw and drill a 1/2" hole in the center of the circle.  Once the drill bit goes through completely, move it around inside the hole to make it slightly larger than 1/2" so that the circle can spin on the dowel.

Drilling the Rest of the Holes
Take the 1/4" drill bit and drill a hole through one of the circles between the 1/2" hole and the perimeter of the circle. Use this as a guide for drilling a hole in the second circle by stacking the circles together and making a small indent with the drill bit in the second circle. Then, finish drilling the hold in the second circle after taking the two circles apart. Once there is one hole in both circles, cut off a small piece of the 1/4" dowel rod and put it through both circles. This ensures that the two circles are lined up.  The other two circles can then be drilled through the second circle.

Attaching the Two Circles
After all of the circles are drilled, cut 3 4" segments of the 1/4" dowel rod. Put these rods through the 1/4" holes in the circles, and glue them into place. The rods should fit tightly, but the glue will help to ensure they stay in place.--MikeBertrand6 (discuss • contribs) 16:48, 14 March 2013 (UTC)

Attaching the String
Measure out a piece of string greater than the circumference of the circles. Nail the string to the center of the outside of one of the circles using a furniture nail. Cover the area around the nail in epoxy.