I had been searching for cheap brushes for a few months to complete this project, but I hadn't found any reasonably priced broom heads or scrub brushed until last week. I spotted some cheap scrub brushes at Target that I thought would work perfectly.
So this project cost me a grand total of $4, with a few scrap materials thrown in.
Step 1: Gather Materials and Tools.
- Flat screwdriver
- #2 Phillips screwdriver bit
- 5/32" twist bit
- 1/8" twist bit
- Circular saw (table saw, miter saw, jig saw, whatever your favorite tool is for cutting plywood)
- #12 x 3/4" pan head sheet metal screws
- 2" construction screws
- 4 cheap scrub brushes
- 6 x 30" piece of 3/4" plywood. (or scrapsin the range of 3 - 4x6" and 1- 6x15")
Step 2: Disassemble the brushes
- Pry the brush from the handle
- When you pry the brush and handle far enough apart, grab the brush part in one hand, the handle part in the other, and pull to separate
Step 3: Cut the Plywood Pieces
2 - 4 x 4" Triangle supports
2 - 4 x 6" side brush holders
1 - 6 x 15" base
Step 4: Set the Brushes in Position.
Then take a pencil and mark where the brushes should be attached. I decided that the side brushes should just rest on top of the bottom brushes. Then remove the side pieces, supports, and brushes and mark the location of the bottom brushes.
Step 5: Attach Brushes to the Plywood
Next use the #12 screws to fasten the brushes to the plywood.
A tip: Drill one hole first and attach the brush to the plywood with a screw before drilling the other holes. This will make it easier to align the pieces.
Step 6: Attach Supports to Brush Sides
Then I attached the supports to the brush sides with 2" wood screws
Step 7: Test Fit a Boot
Notice in the picture that the side supports actually extend over the edge of the base. I marked the support with a pencil and cut off the excess to make it easy to align for the final assembly
Step 8: Attach Sides to Base
Step 10: A Different Material
The changes I made were:
- I used 1" wood screws (3/32" pilot hole) instead of 2"
- I ended up counter sinking the wood screws because the plastic started splitting as the head drove into the plastic. See second picture in this step.