Having a homemade extension cord reel can be incredibly handy for managing long extension cords and preventing tangles and messes. A homemade reel allows you to neatly wrap up and store any extra cord length when not in use. With some basic tools and materials, making your own extension cord reel is an easy DIY project.
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Materials Needed
Making a homemade extension cord reel is a relatively simple project that only requires a few basic materials:
- 3/4 in. x 2 ft. x 2 ft. plywood (or other sturdy wood) – This will be used for the reel base.
- 3 in. PVC pipe – This will form the reel barrel. Make sure the length is slightly longer than your extension cord.
- Eye screws or cup hooks – These will attach the reel to the base. Get a size that fits into pre-drilled holes in the PVC pipe.
- Zip ties or metal hose clamps – Used to attach the PVC pipe reel to the base.
- Wood glue
- Wood screws
- Sandpaper
- Paint/stain (optional)
You may also need some basic tools like:
- Hand saw or miter saw
- Drill with various drill bits
- Pencil
- Safety glasses and dust mask
- Clamps
- Tape measure
- Sanding block
Cutting the Plywood Base
Start by cutting your plywood into two 18 in. x 18 in. squares – this will form the base. Use a ruler and pencil to measure and mark cut lines. Clamp the plywood down securely to a work surface before cutting with a hand saw or miter saw. Wear safety glasses during cutting.
You can round the corners slightly for a nicer look. Use a sander or sanding block to smooth cut edges of the base pieces. Wipe away any dust.
Drilling the PVC Pipe
Next, mark a line lengthwise down the PVC pipe to use as a guide. Use a drill to make pilot holes approximately 6 inches apart along the line. Make sure to hold the PVC pipe securely while drilling. Insert eye screws or cup hooks into each pilot hole – these will hold the extension cord in place.
At both ends of the PVC pipe, drill larger holes just wide enough for zip ties or hose clamps to fit through. These larger holes will be used to attach the reel to the base.
Assembling the Reel
With the base pieces and PVC reel ready, you can now assemble them together:
- Apply wood glue to the edges of the plywood base pieces and clamp together so they form one wider base. Allow the glue to fully dry.
- Mark the center point on the base, and drill pilot holes a few inches in from each edge (four pilot holes total).
- Turn the base over so the back side is facing up. Mark locations several inches from the edges for eye screw holes. Drill pilot holes at each mark.
- Screw an eye screw into each pilot hole, allowing the threads to stick up from the back side of the base.
- Place the PVC pipe reel in the center of the base. Thread zip ties or hose clamps through the holes at the ends of the pipe and around the base, securing the reel to the base.
Finishing Touches
With the reel fully assembled, just add a few finishing touches:
- Sand any rough edges on the base.
- Apply wood stain, paint, or other finishes if desired.
- Allow any finishes to fully dry.
- Wind your extension cord around the PVC reel barrel and secure with the eye screw/cup hook holes.
- Flip the reel over and hang via the eye screws on the back.
Using Your Extension Cord Reel
Your homemade extension cord reel is now ready to use! To operate it:
- Plug your extension cord into an outlet as normal.
- Slowly pull cord from the reel, unwinding as much length as needed.
- Secure unwound length by wrapping around eye screws/cup hooks.
- When finished, unwind cord from hooks and slowly wind back around the reel barrel.
- Hook onto eye screws on back to hang vertically and neatly store.
Tips for smooth operation:
- Make sure cord is wound straight around barrel without kinks.
- Don’t overfill – leave a little slack when winding up cord.
- Roll up excess length in loops before winding final length around reel.
- Hang reel near outlet to avoid excessive cord lengths.
Conclusion
Constructing your own extension cord reel is an easy and inexpensive DIY project. With just basic tools, materials, and some handy skills, you can make a reel that keeps extension cords neatly organized. Just follow the step-by-step instructions to cut materials, assemble the reel, and add finishing details. In no time you’ll have a handy homemade reel that prevents extension cord tangles and damage. Use this DIY reel to conveniently store and deploy extension cords in your garage, workshop, or anywhere else you need an extra hand with cord management.
Extension Cord Reel FAQ
What size PVC pipe should I use?
The ideal PVC pipe size depends on your extension cord length and thickness. For standard household extension cords up to 25 feet, a 3 inch diameter PVC pipe with a length around 30 inches should work well. Go with 4 inch diameter PVC if using a longer or thicker cord. Just make sure the pipe is slightly longer than your cord.
How far apart should the eye screw holes be?
A good spacing between eye screw holes is about every 6 inches along the length of the PVC reel. However, adjust this as needed based on your cord thickness. Keep holes close enough so the cord is held snugly in place when wound around the reel.
What’s the best material for the base?
Plywood is an ideal material for the base – it’s inexpensive, easy to work with, and sturdy. You could also use boards made of pine, oak, or other woods. Avoid weaker materials like cardboard that won’t hold up over time. The base should be made of a solid, strong wood.
Should I secure the reel to the base?
Yes, it’s important to securely fasten the PVC reel pipe to the wooden base. This prevents the reel from slipping as cord is pulled. Use sturdy zip ties or metal hose clamps through holes at the ends of the pipe to anchor it to the base.
How do I hang the extension cord reel when not in use?
Install eye screws into pilot holes on the back side of the wooden base. Leave enough length so the threads stick out. You can then flip the reel over and hang it vertically by slipping the eye screws over a secure mounting hook, nail, or other projection when not in use.
Can I decorate or paint my homemade reel?
Absolutely! Staining, painting, or other DIY decor techniques are a great way to customize your extension cord reel to match your space or style. Get creative with colors and designs – just be sure any finishes are fully dry before use.
Safety Tips
When making and using your homemade extension cord reel, keep these safety guidelines in mind:
- Unplug the cord when performing any work on the reel or cord.
- Use caution handling power tools, wearing eye protection as needed.
- Don’t overload the reel – leave a little slack when winding cord to avoid damage.
- Check for damage before each use. Replace worn cords.
- Don’t exceed the cord’s length rating.
- Only use the reel with proper gauge extension cords.
- Install reel near outlet to avoid excessive cord lengths.
Following basic safety practices will keep your homemade reel functioning safely for years to come!
Customizing Your Reel
One benefit of building your own extension cord reel is the ability to customize it! Here are some ideas for modifications:
- Add more/larger hooks – For thicker cords or extra wrapping positions.
- Include cord storage – Attach some PVC tubing to hold wound up excess cord.
- Make it collapsible – Hinge the base in the middle for folding storage.
- Use a lazy susan – Rotating bases make unwinding cords super easy.
- Integrate a power strip – Attach a power bar to the base for built-in outlets.
Get creative with handy add-ons to enhance your reel’s functionality!
Troubleshooting
Here are some common problems and solutions for DIY extension cord reels:
| Problem | Possible Cause | Solution |
|---|---|---|
| Cord won’t wind up evenly | Cord is kinked or twisted | Unwind and straighten cord before re-winding |
| Reel wobbles or falls over | Base is uneven or reel not secured | Check base is flat and secure reel tightly |
| Cord loosens during use | Hook spacing too wide or hooks are wrong size | Re-space hooks as needed and ensure hooks fit snugly |
| Reel doesn’t rotate smoothly | Contact points are binding or sticking | Lubricate with wax or silicone spray |
Address any issues promptly to ensure safe operation and prevent damage.
Conclusion
Constructing your own DIY extension cord reel is a satisfying project that yields a handy tool for your home or workshop. Following the steps outlined, you can build a custom reel tailored to neatly store any extension cord. Use quality materials, measure precisely, and work safely to create a reel that will last for years. Keep your workspace clutter-free and your cords tangle-free with this do-it-yourself project. The ability to customize your reel means you can add convenient features to perfectly suit your needs. Apply your creative skills and handyperson’s know-how to build the ideal homemade extension cord reel.
