Step 1: Tools and Materials
* Old CDs
* CD labels
* Packing tape
I used the following tools:
* Calipers (or other measuring device)
* Dremel (with high speed cutter, cutting wheel and grinding drum)
* De-burring tool
* Dust Collection System (Optional)
Step 2: Measure
I then measured the diameter of the center hole in the CD.
The difference in size is the amount of material you'll need to remove from the CD. In my case it was 47/100ths of an inch. I rounded up to half an inch.
Now an error crept in, in my measuring. I measured a half an inch from the edge of the hole in the center of the CD. I should have measured a quarter inch so I would end up with a total of a half inch of material to be removed. The consequence is I have a much bigger hole than I needed. (Unfortunately I didn't notice anything was amiss until I was putting it on the rod).
This measuring error happened to coincide with the transition from the clear plastic to the data area of the CD so I didn't bother to mark the outline. It was already done for me. When I make more of these (assuming Mrs. RadBear wants more) I'll need to mark the plastic so I'll know how much to remove.
Step 3: Cutting
I then used a sanding drum and a deburring tool to smooth down the edges of the new hole.
With hole smoothed I used a cutting disc to cut from the edge of the new hole to the edge of the CD. This cut allows the CD to be placed over the closet rod by flexing the edges of the cut in opposite directions. I then cleaned up the cut with a file.
Step 4: Labels
So follow the instructions that come with your labels to create the kick-ass closet divider label you've always wanted and print out two copies of it. (I'd be more specific but with so many different kinds of labels, programs and printers out there, you're on your own for this.)
Put the labels on either side of the CD doing your best to cover the surface completely. Use a utility knife to trim the excess label material from the center hole.
Then cover both sides of the CD with packing tape. (This will keep the ink from transferring to the clothes and keep the labels from getting worn away.) Use your utility knife to cut the excess tape away from the outer edge of the CD and the center hole. With that done use the knife to cut through the tape and label that covers the slit in the CD.
Flex the edges of the slit in opposite directions and slide it over the closet rod.