Hi everyone! This project came out as a solution of a dire problem that I had – a tangled earphone. So, I sketched a design for an earphone holder; something small, practical and looks good. Since I love miniatures I have an idea of making it into a shape of wooden cable drum. The diameter of the drum’s barrel is only 10 mm, with a flange diameter of 40 mm and an inside traverse of 15 mm.

Before I start the instructions, I would like to clarify one thing. I made this project with basic hand tools, and it does take some time to finish it. You can however use power tools – hand drill, Dremel tools etc; to complete the job. Which does make it a lot easier and faster.

Step 1: Gather Your Tools & Materials

Material:

Craft Sticks

Tools:

Cutter
Craft Knife
Cutting Mat
PVA White Glue
Small Brush
Paper Clips
Tweezers
Needle File – a Flat type and a Half Round type
Masking Tape

Step 2: Making the Cable Drum’s Flange

First of all, draw a template on a paper, cut it out, and trace it over a line of craft sticks.
Trim the sticks with cutter. Do not attempt to cut the shape with the cutter. You’ll break the stick.
Cut the sticks into halves. Now with smaller width, it will be much easier to cut the sticks without breaking it.
Use the flat file to finish up the edge.
As for the barrel hole, use the half round file to make the shape.
Once all done, arrange the sticks into its shape.
Apply PVA glue on the surface. Do this on one side of the sticks only.
Make two of these flanges.

Step 3: Making the Cable Drum’s Barrel

Cut the craft stick of a size of 15 mm – you’ll need 3 of it.
Cut it into halves, arrange it in a line and apply PVA glue.
Once dried, roll it over into a cylindrical shape. Glue both ends. Use masking tape if necessary to hold the shape.

Step 4: Attach the Barrel

Glue the barrel onto the middle of the first flange.
Add another layer of sticks on top of the first one. Arrange it in perpendicular to add strength to the shape.

Step 5: Attach the Second Flange

Glue the second flange to the other end of the barrel.
Same as the previous step, add another layer of sticks for the second flange. Use paper clips to hold it while it dries.

Step 6: Strengthen the Barrel

Add another layer of sticks to the barrel. Use tweezers to easily glue the sticks onto its place.

Step 7: Add a Groove

As the final touch use the file to create a small groove at one end of the flange. This is to run the earphone cable through the drum.
I didn’t further sand the cable drum nor add a layer of lacquer as I prefer the rough looks that it had. You may do these additional steps if you wanted to.