How to make a simple pulley at home: 2 easy methods for lifting heavy objects.

If you're looking for a way to make a pulley to lift lighter objects, this article will help you quickly understand and make one at home. A pulley is a simple machine that distributes force, allowing you to pull, lift, or move heavy objects without expending too much effort. With just a few common items, you can easily create a basic pulley or a double pulley to halve the pulling force. The article below will guide you step-by-step, in an easy-to-understand way suitable for everyone.

Method 1: How to make a simple fixed pulley at home

Step 1: How to prepare the pulley shaft from a coat hanger or long stick

1. Cut the bottom of the wire coat hanger in half to make the shaft.

• Use metal shears or wire cutters to cut off the horizontal bar at the bottom of the coat hanger.

• Cut it right down the middle to make it easier to thread the bobbin (or pulley) inside.

• Keep the top part of the coat hanger in place so that it can be hung when using the pulley.

• When cutting, do so slowly and hold the hanger firmly to prevent the wire edge from snapping back and causing scratches.

• This is a simple and common method when trying to make a pulley at home because coat hangers are easy to find and bend.

2. Use a broom handle as a pulley axle if you don't have a coat hanger.

• Place a broom or a long wooden stick between two tabletops or shelves.

• Adjust the rod so that the tip rests firmly on the two support points.

• Place a heavy object on one end of the broom to secure the shaft and prevent it from rolling when the cord is pulled.

• This method is suitable when you want to try making a simple pulley without cutting metal.

3. Safety precautions when preparing the pulley shaft.

• Always keep your hands away from the cutting area when using metal cutting scissors.

• Choose a shaft material with sufficient rigidity to withstand the pulling force of the load.

• Place the shaft on a flat, non-slip surface for easy and safe operation.

Step 2: How to assemble the thread spool for the pulley wheel

1. Thread the yarn through the cut bottom of the hanger.

• Gently separate the two ends of the wire at the cut point to create a gap of sufficient size.

• Slide the spool of thread into the middle, making sure the spool hole is wide enough for the garment hook to pass through.

• Make sure both ends of the coat hook go through the center of the reel so the wheel spins smoothly when the cord is pulled.

2. Bend and secure both ends of the wire to hold the spool of thread.

• Use pliers to firmly grasp the end of the coat hanger and bend it into a small hook shape.

• Check that the thread spool doesn't fall out but still spins smoothly.

• Bend the hanger little by little to avoid breaking or bending it too much.

3. Choosing the right spool when making a pulley at home.

• You can repurpose old sewing thread spools, jute twine, or small nylon cords.

• If you don't have a spool of thread, you can buy one at a craft supply store in various sizes.

4. Replace the thread spool with a specialized pulley wheel.

• If you want a pulley that operates more stably and can withstand greater loads, you can buy ready-made pulley wheels at a building materials store.

• This type of wheel typically has deep grooves, which prevent the pulley from slipping and is suitable for those looking for a more robust and durable pulley system .

Step 3: How to hang the pulley onto the support bar for use.

1. Choose the appropriate support bar.

• Find a clothes rail, wooden rod, or round tube inside the closet.

• If none are available, you can place a wooden bar or dowel between two tables or shelves.

• Prioritize a sturdy bar so that the pulley system does not vibrate when lifting heavy objects.

2. Secure the support bar to prevent rotation.

• If the bar tends to rotate or slide, place a heavy object on one end to keep it stable.

• Check the sturdiness of the bar before attaching the pulley, especially when you're experimenting with homemade pulley systems for lifting light objects.

3. Hang the pulley using the provided hook.

• Use the hook on the coat hanger to attach the pulley directly to the support bar.

• Make sure the coat hangers are securely attached to the bar and the pulley is wound straight so the zipper runs smoothly.

• Gently pull a short section of the rope to check that the pulley wheel rotates smoothly and without misalignment.

Step 4: How to thread the rope through the pulley to begin using it.

1. Prepare a piece of string of suitable length.

• Cut a piece of string or twine that is twice the distance from the floor to the bottom of the coat hanger.

• This length allows the rope to wrap around the pulley completely, with plenty of room left over for pulling or hanging heavy objects.

• The softer and straighter the rope, the smoother the pulley wheel will rotate.

2. Thread the rope through the pulley wheel.

• Bring one end of the thread up and place it through the groove of the spool.

• Adjust the rope so that both ends hanging down are of equal length.

• Pull gently to check if the rope slides smoothly and the wheel spins effortlessly.

3. Attach small hooks for easier hanging of heavy objects (optional)

• If you want to do more experiments with the pulley, you can attach a small metal hook to one end of the string.

• Hooks help you hang heavy objects faster, more stably, and easily change the load during testing.

• Make sure to secure it tightly so the hook doesn't come loose when pulled.

4. Choose the right type of rope for your homemade pulley.

• You can use thread, paracord, jute rope, or thin twine depending on the materials you have available.

• Hemp rope or twine will be stronger, suitable if you want to try making a pulley system to lift heavy objects more stably .

Step 5: How to attach a weight to the rope to test the pulley.

1. Choose a suitable weight for the test.

• Prioritize lightweight items such as a few washers, a thin notebook, or similar small objects.

• Avoid using excessively heavy objects, as metal coat hooks can easily bend, causing the pulley to operate less stably.

• Choose an object with a secure attachment point so it won't slip when pulled.

2. Secure the rope to the heavy object.

• Use the prepared end of the rope and wrap it around the heavy object several times to increase grip.

• Tie a single or double knot to ensure the object doesn't fall out while lifting.

• Gently pull to check if the button is tight and doesn't slip.

3. Let the other end of the rope hang freely.

• The end of the rope, which is not tied to a weight, is lowered straight down the other side of the pulley.

• This is the end of the rope you'll hold to test the pulley, allowing you to observe how the pulley distributes the force.

4. Place the heavy object on the floor before you begin.

• Before pulling, always place the heavy object on the floor to avoid a sudden jolt.

• When you pull the rope up, you'll feel less lifting force thanks to the pulley's force distribution mechanism.

5. Quickly understand the pulley principle during testing.

• Pulleys help you reduce the force required by distributing the load across both sides of the rope.

• When you pull the other end of the rope, the force is distributed evenly, making it much easier to lift heavy objects, especially in simple pulley setups at home .

Step 6: How to operate a pulley to lift heavy objects

1. Pull the rope straight to lift the object.

• Grab the end of the rope that is hanging freely and pull it straight down.

• When you pull, the pulley coil rotates around the coat hook's axis, reducing friction and making the lifting effort lighter.

• Keep the rope straight so the wheel spins smoothly and the heavy object moves steadily upwards.

2. Secure the end of the rope if you want to hang a heavy object in mid-air.

• If you want the heavy object to remain suspended in the air, tie the end of the rope you are pulling to a secure, fixed point.

• Choose a secure location for tying the item, avoiding lightweight or easily tipped-over objects.

3. Experiment with different weight levels.

• Change the weight to observe the effect of the pulley.

• Start with a light object and gradually increase the weight, avoiding using objects that are too heavy, which could bend or deform the coat hanger.

• Note down the feeling of the pulling force at each weight level to understand how the pulley distributes the force.

4. Identify the force-assisting mechanism of pulleys.

• When you pull down, the force is evenly distributed across the two branches of the rope, making it easier to lift heavy objects compared to pulling directly.

• This is an important principle in making pulleys at home and is also the reason why pulleys are widely used in everyday life and mechanical experiments.

Method 2: How to create a simple, effortless double pulley.

Step 1: How to prepare a stand using a cardboard box to make a pulley.

1. Choose two cardboard boxes of the same size.

• It's best to use two boxes of similar thickness, such as cereal boxes, storage boxes, or small cardboard boxes.

• Uniform thickness helps homemade pulleys stand more firmly and distribute force better during testing.

2. Place the two boxes parallel to each other on a raised surface.

• Choose a flat surface on a table or shelf to place the two boxes about 13–15 cm apart.

• Adjust the box so that the edges run parallel, avoiding any angle deviations as this can cause the pulley to operate erratically.

• This distance is sufficient to create space for lifting heavy objects while maintaining the system's balance.

3. Prioritize boxes with good thickness to ensure safety.

• The thicker the box, the better it can withstand pressure and the less likely it is to be dented or torn when the zipper is in operation.

• The thin box is easily torn, especially if you use a stiff wire or test it with heavier objects.

• If you plan to test it multiple times, choose a thick cardboard box for increased durability.

Step 2: How to create a pulley shaft using a pencil and thread

1. Prepare the thread for making the pulley wheel.

• Use an old wooden spool of thread or a new spool purchased from a craft supply store.

• Make sure the hole in the middle of the reel is wide enough for the pencil to pass through and rotate smoothly.

• The more uniform the thread and the more clearly defined the grooves, the less likely the drawstring will slip during operation.

2. Thread the string through the middle of the pencil.

• Use a straight pencil that is not bent and has a clean lead.

• Thread a pencil through the center of the spool of thread to create an axle that allows the wheel to spin smoothly.

• Test by gently rotating the spool of thread to ensure it can spin freely around the pencil.

3. Replace the spool of thread with a specialized pulley wheel (if available).

• If you want a more durable system or to try lifting heavier objects, you can purchase pulley wheels at a building materials store.

• This specialized wheel type has deep grooves and a standard profile that ensures stable rope movement, making it suitable for pulley systems that provide better lifting force.

Step 3: How to create holes to attach the pulley shaft to the two cardboard boxes.

1. Prepare a sharp pencil to poke holes.

• Use a sharpened pencil as a tool to make holes.

• Hold the pen steady and insert it slowly to avoid tearing the box or misaligning it.

• Working slowly helps to create a clean edge around the hole, providing a good support point for the pulley shaft.

2. Create the first pair of holes on both boxes.

• Make a hole in the side of the first box, at a position level with the pulley shaft where you want to place it.

• Move on to the second box and make a hole in the corresponding position, so that the two holes are aligned with each other.

• Aligning the pencil shaft ensures that the pulley reel is centered and rotates smoothly.

3. Create another pair of holes 5–7 cm away from the first pair.

• Measure or estimate a distance of 2–3 inches (5.1–7.6 cm) from the first pair of holes.

• Create a new pair of holes on both boxes, making sure they are aligned with each other.

• The second set of holes allows you to change the height or experiment with different axle mounting positions when making a pulley at home .

4. Notes on creating holes in cardboard boxes

• The thicker the box, the gentler you need to be when punching holes to avoid denting it.

• Avoid rotating the pencil too forcefully to prevent tearing the edge of the hole, which could affect the stability of the shaft.

Step 4: How to attach the pencil shaft and pulley to the two cardboard boxes

1. Insert the blank pencil into the first pair of holes.

• Insert the eraser tip of the pencil through the hole in the first box.

• Continue pushing the pointed end through the opposite hole on the second box.

• Adjust the pencil so that it is perpendicular to the side of the box and not crooked.

• This is the fixed shaft, which helps the box maintain a stable distance when you install the pulley wheel.

2. Insert the pencil with the spool of thread into the remaining pair of holes.

• Take the pencil with the spool of thread attached in the middle and thread it through the second pair of holes on both boxes.

• Make sure the spool of thread is centered in the pen, not touching the edge of the bobbin case, so that it spins smoothly.

• Check that the distance between the two boxes remains at the original level of 13–15 cm.

3. Keep the pencils securely in the box.

• If the pencils are loose or easily slip out, insert modeling clay into the inside of the box to secure them in place.

• Make sure the pen stands firmly and doesn't vibrate when pulling the thread through the spool.

• Secure fastening ensures that the pulley operates stably and does not become misaligned.

4. Check for balance before use.

• The two pencils need to be parallel and perfectly perpendicular to the sides of the box.

• The pulley coil should rotate smoothly when tested by hand.

• If you notice rubbing or misalignment, readjust the hole or the distance between the two boxes.

Step 5: How to tie the rope and thread it through the pulley wheel

1. Tie one end of the string to a pencil that doesn't have a spool of thread.

• Cut a piece of wire twice the height from the floor to the top of the box.

• Wrap the string around the empty pencil and tie a tight knot so the string doesn't come loose when pulled.

• You can also tie the string before inserting the pen into the case if it makes the process easier.

2. Thread the other end of the rope through the pulley.

• Take the free end of the thread and place it on the spool groove on the second pencil.

• Adjust the thread so that it sits correctly in the groove, allowing the spool to spin smoothly when pulled.

• Gently pull the wire to check that it runs smoothly and doesn't get caught on the edge of the box.

3. Ensure the knot is securely fastened before use.

• Pull gently a few times to test the tightness of the knot.

• If the rope slips, tie an extra double knot for increased grip.

4. Check the cord length for smooth operation.

• The two ends of the rope should be long enough for you to pull without getting tangled.

• The standard length ensures that the pulley model operates smoothly in lifting tests.

Step 6: How to attach paper clips to the string to create a hanging point for the weight.

1. Thread the paperclip through the string.

• Take a paperclip and thread a string through the middle loop of the clip.

• Keep the wire straight so the clip slides easily without twisting.

• This step involves creating a suspension point for the weight when you're testing a pulley.

2. Slide the paperclip between the two pencils.

• Pull the paperclip along the string until it sits precisely between the two pencils in the pulley model.

• To temporarily clip the paper to the table while you complete the other preparation steps.

• This position allows the paper clamp to move smoothly when the pulley is in operation.

3. Secure the paperclip if you want to keep it in place.

• If you don't want the paperclip to slide when you pull the string, tie a small knot just above or below the clip.

• The knot holds the clamp in place, which is very useful when you're trying out DIY pulley projects that require precisely hanging heavy objects.

4. Check the slipperiness of the rope before use.

• Gently pull both ends of the string to see if the paperclip is in the correct position or has been rotated out of place.

• Adjust the fasteners (if any) to ensure stable operation when hanging objects.

Step 7: How to hang a heavy object on a paperclip to test the pulley model.

1. Bend the paperclip to create a hook.

• Gently straighten one end of the paperclip with your fingers to create a small hook.

• Keep the rest of the paperclip intact so that it slides steadily on the wire.

• This hook will be used to hang a heavy object in the pulley experiment.

2. Hang small, heavy objects on paperclip hooks.

• Insert small objects such as washers, metal beads, or similar objects with holes into the paperclip hook.

• Make sure the heavy object is positioned close to the hook and won't easily fall when the rope is pulled.

• Avoid using excessively heavy objects to prevent tearing the cardboard box or breaking the strings.

3. Place a heavy object on the table surface before operating.

• When first hanging an object, let the heavy object rest on a table surface to avoid a sudden jerk when you pull the string.

• This method allows you to better control the forces and clearly observe the mechanism of the model's operation.

4. Use the same weight to compare the efficiency of the pulleys.

• If you've experimented with a single pulley before, use the same type and the same weight.

• This makes it easy to see the difference in pulling force between a single pulley and a complex pulley system made from two cardboard boxes.

5. Safety precautions when selecting heavy objects.

• Use only moderately heavy objects to avoid damaging the cardboard box or breaking the string.

• If you notice any signs of bending, tearing, or misalignment in the cardboard box, reduce the weight immediately.

Step 8: How to operate a cardboard pulley to lift heavy objects.

1. Pull the string through the spool to lift the object.

• Hold the free end of the thread and pull it straight down so that the thread slides through the spool groove.

• When you pull, the pulley coil rotates around the pencil, reducing friction and making the lifting effort lighter.

• The heavy object attached to the paperclip will be lifted steadily thanks to the even distribution of force on the two branches of the rope.

2. Understand the principle of double pulleys to optimize pulling force.

• Because one end of the rope is fixed to the pencil, this model requires only about half the force compared to a single pulley.

• The force is evenly distributed between the spool of thread and the fixed piece of string, making it easier to lift the object, but requiring you to pull the string twice as far as the object will travel.

• This is a key difference when you want to compare different methods of making pulleys at home and understand the effectiveness of each model.

3. Try adding more thread and a pencil to reduce the lifting force.

• You can add more thread spools or pulley shafts to further reduce the force required.

• Each additional spool of thread will provide a lighter pulling force, suitable if you want to experiment with lifting heavier objects while still remaining within the safe limits of the cardboard box.

4. Use a spring dynamometer to measure the tensile force (optional)

• Attach the free end of the string to the hook of the spring scale.

• Pull the string and observe the reading on the dynamometer to know exactly how much force you are using to lift the object.

• This is a simple way to better understand the principle of force distribution in pulleys and is very useful in mechanical experiments.

5. Perform a safety check before each test.

• Make sure the cardboard box is not torn, the pencils are not crooked, and the string is not frayed.

• If you find the system is no longer stable, reduce the weight or replace the cardboard box with a thicker one.

References

1. https://sciencing.com/make-pulley-children-5896241.html
2. https://www.teachengineering.org/lessons/view/cub_simple_lesson05
3. https://www.scientificamerican.com/article/lighten-the-load-with-a-pulley

Translated by: Rowan Hudson Le .