Introduction: How to Make a Two-Part Magnetic Stapler
One limitation of a typical office stapler is that it only lets you staple about 3 1/2" into the paper. This isn't enough for a lot of projects. If you want to put together your own comic book or a large banner, you are usually stuck stapling your project onto a piece of cardboard or carpet and then bending the legs of the staple by hand. They do sell extra long staplers or staplers with swivel heads but they still have their limitations.
A better option would be to make a stapler with a detachable base. The base would be positioned under the paper and aligned to the top half of the stapler with magnets. This would allow you to staple any area of a project regardless of location. So in this project, I am going to show you how to convert a standard stapler into a two part magnetic stapler.
Step 1: Materials
Four strong magnets (preferably rare earth)
Drill and bit set
file or grinder (optional)
Step 2: Separate the Two Halves of the Stapler
Most staplers are held together at two points on the stand where the metal is punched through holes in the base plate and crimped in place. To separate the two halves of the stapler, use a drill bit that is a little bigger than the holes to drill out these areas. On most staplers you will need to drill out both the top and bottom sides to remove all the metal. At this point the stapler should come apart.
Step 3: Drill Holes for the Magnets
If your magnets are larger than the holes that you just drilled, then you need to widen the holes so that the magnets will fit inside. The easiest way to do this is to drill them out with larger drill bits. If the bit gets stuck on a metal bur, turn the plate around and resume drilling on the opposite side. After drilling, use a file or grinder to remove any sharp edges. This will ensure that both halves of the stapler have a flat surface without any metal sticking out.
Step 4: Attach the Magnets
Two magnets will be located in the holes of the base plate with the top side of the magnet flush with the top side of the base plate. Two other magnets will be located in the holes of the stand with the bottom side of the magnet flush with the bottom side of the bottom side of the stand plate.. In some cases, the spring may be in conflict with the desires position for the magnets. If this is the case, you can remove the spring with a pair of pliers.
In order to ensure that the magnets will be flush the plates, first apply a piece of tape to the top side of the base plate and a second piece of tape to the bottom side of the stand plate. Then fit the magnets in place and apply super glue all around the edges. Wait until the glue is fully cured before reassembling.
Step 5: Use Your Finished Two Part Magnetic Stapler
After the glue dries, put two halves back together and try stapling something. If all went well, everything should line up as it normally would. Whenever you want to staple a large or oddly shaped project, place the base of the stapler underneath the project, and place the upper half of the stapler on top of the project. Then use the magnets to align the two parts. The stronger the magnets are the more accurately the two halves will align. This kind of design gives you a lot more freedom than a traditional stapler.