Paper Towel Holder

Directions Prepare base

1. To make the paper towel unit look less blocky, we need to round off the base of the paper towel holder. The easiest way to do this is to use a router with a concave curve bit and run it down the length of each side.

Cut mechanism groove into side pieces.

1. The side pieces hold the key to the paper towel mechanism. Each side piece needs a groove added in it  that will allow the main dowel rod to slot in (by pushing straight back) and then drop down into the final "locked" position. To make this groove, use a 3/8" router bit, cutting the groove to a depth of 1/4". There is no easy way to make this slot (although a router table helps) and the key is to cut the groove slowly, with patience, having first marked the path of the slot. When cutting the slot in the second side piece, remember that this should be a mirror image of the first, not a direct replication.

Cut curve in side pieces

1. Once the slots are cut, round off the top of each side into a curve (diameter 3") with a jigsaw or a band saw. Once done, cut the single length of wood (10 1/2" long) into two separate side pieces (if you did not do this earlier).

Attach sides to base

1. Attach the side pieces to the ends of the base unit using either a biscuit join or dowels (thus hiding the joint)

Prepare Rod

1. Drill a hole 3/4" deep and 5/16" diameter in the center of each end of the main rod dowel. The easiest way to find the center of this 1 1/4" diameter dowel is to cut out a 1 1/4" by 1 1/4" square of paper and draw a line from each corner (thus forming and "X"). Place this square of paper over the end of the dowel, and the center of the X is the center of the dowel end. Once you have drilled the holes, glue the small dowel ends in to them, so that the small dowels protrude 1/4". This dowel until should now slot into the side grooves made earlier, completing the project.
2. To finish the project, sand and varnish it.