This is a remake of A Storage Carousel. It has been changed from metric to English measurements and preset dimensions for cutting on a laser printer. This is also similar to Rotunda. The trays are 10-1/2" L x 2" D x 3-1/4" W. When completed, the entire carousel is about 16-1/2 inches high.

Supplies

laser cutter
1/8 inch Baltic Birch plywood
5/8 inch #6-32 bolts
#6-32 lock nuts
3/8 inch diameter x 4 feet length wood dowel
wood glue
socket wrench
screw driver

Step 1: Cut Out All the Pieces

Shown are the pieces for one of the carousel trays. Six of these are needed. There are four stand pieces that will be glued together to form two layered stand pieces. Note that the end pieces for the trays are cut from the stand pieces. The two disk pieces are for mounting the accessory trays and the 3/4 inch spacers to be used are cut from these disks. These spacers will be placed between the trays and the carousel discs. Two large spacers are used between the carousel discs and the stand.

Step 2: Prepare Stand Pieces

Apply an even layer of wood glue to the entire surface of one of the side pieces. Use a couple of short segments of dowel to make sure the two pieces are aligned and press together. Weight the two pieces down on a flat surface to prevent warping while the glue dries. Repeat this for the other stand pieces.

Step 3: Assemble the Trays

Glue the trays together as shown. You will need six trays.

Step 4: Connect the Trays to the Discs

Insert a 5/8 inch bolt through the disc, a spacer, and the end of a tray. Do not glue the spacer to anything. Loosely tighten a lock nut onto the bolt. Repeat this for the other end of the tray and the other disc. The lock nuts will be tightened up in a later step. Complete this for attaching the remaining trays.

Step 5: Mount the Carousel to the Stand

Cut three 11-13/16 inch long 3/8 inch diameter wood dowels. Slide one of the dowels through the center hole of one of the carousel disks, and through one of the large spacers. Continue to slide the dowel through to the center of the other carousel disk, the other large spacer and glue into the stand. Apply glue to the remaining stand hole and attach the stand to the dowel. Avoid gluing the spacers to anything. Attach the two remaining dowels to the bases of the stands.

Step 6: Adjust the Tray Movement

Using a socket wrench and screw driver, tighten the lock nuts on each tray such that the are holding the tray, spacer, and disc together yet allow the tray to move freely.