Round reel Ø 260

Material:
2 discs Ø260mm in ply-wood
4 discs Ø140mm in ply-wood
2 supports for tubes assembly
2 handles wood screws with flat countersunk head :
6 screws Ø4 x 20mm 6 screws Ø5 x 80mm wood glue

Fabrication

Draw and cut the discs
Drill the center hole Ø4.5mm

Glue the 4 discs Ø140mm centered with a Ø4mm bar.
Smoothing with rasp the hub, and finishing by sanding.(recover the sawdust)

Profiling the two discs Ø260mm with rasp and sanding.
Glue the two discs Ø260mm on the hub, and center with the Ø4mm bar.

Setting on each sides 3 screws Ø5x80mm divided 120° on a circle 100mm diameter. The screws on the opposite side are 60° offset. It must be drilled a Ø3.5mm deep hole for the screwing part, and a Ø4mm hole for the top smooth part. The screws are drove in 2 to 3 mm deeper.

The center hole can be blocked with two rods Ø4mm.

Note: With 19mm thick ply-wood, the width of the reel will be 120mm. With 22mm plywood, the width of the reel will be 136mm.

Finishing

Mix the sawdust with some wood glue to get a smooth and homogeneous paste (half a glass of sawdust is needed). Cover the corner between the hub and the sides with the paste, 5 to 6mm thick, and smooth down with a wet finger.
Fill the holes of the screw heads.
Let dry a full night.
When it is well dried, sand it.

Drill a hole Ø4mm starting from a side, and coming out in the hub. On the side, set a box Ø8mm deep at the entrance of this hole.
Sand up to a good finish. This hole will be used to fix the start tip of the line on the reel.

Varnish the whole reel(with a boat quality varnish). Hang it using the side hole during its drying.

Assembly the supports of handles on the hub.

Mount the handles.

Entering in the hub side, drive through the tip of the line in the hole, and getting it out off the side, make a wedging knot.
Wind the line.