How To Build a DIY Cat Wheel

Cut plywood

• Cut 4- by 8-ft. plywood into two 4- by 4-ft. pieces with a circular saw.
• Find and mark the centers with your tape measure.
• Make a compass out of cardboard to draw circles on 4- by 4-ft. plywood pieces:
  • Cut cardboard into a narrow strip longer than the radius of circle.
  • Attach one end to center of plywood with screw or nail.
  • Measure 21 inches from center, poke a hole for the pencil and draw a 42-in. circle with the compass.
• Cut both plywood pieces into 42-in. circles using a jigsaw or router.
• Adjust the compass radius and draw a 39-in. circle on one piece of plywood, and a 39-in. and 36-in. circle on the other.
• Cut out the 36-in. circle, leaving a 6-in. ring of wood. Set aside the 36-in. circle to use for the base.

Cut dowels and 2x4s

• Tape three to five dowels together into bundles.
• Cut into 1-ft. sections using a miter saw.
• Cut one 2×4 into four equal pieces.
• Cut the other 2×4 into one 34-in. piece. Reserve the other end for later.

Drill holes

• Mark the 39-in. lines on both plywood pieces at 2-1/2-in. intervals (if using 1-in. dowels).
• Use the 1-in. Forstner bit to drill holes halfway through both pieces of plywood on your marks.
• Cut the 6-in. ring piece into four sections to make it easier to glue in the next step.
  • I had difficulty gluing the top ring piece onto dowels, so I cut it in sections. If you can do it and have enough clamps, this step is optional.

Glue dowels

• Place a 42-in. circle flat on workbench with the center mark up.
• Do a dry run with dowels, fitting them into holes to make sure they fit and will stand evenly.
• Apply wood glue to the holes in one quarter section. Insert dowels, turn and push to fully seat dowels in holes.
• Apply wood glue to top of dowels and place one top ring section.
• Clamp the section in at least two spots, making sure dowels are maintained at 90-degree angle to base.
• Repeat with other sections. Clamp ring sections together and tack with staples to hold as glue dries.

Build base

• Just like with a cat tree, a cat wheel needs a sturdy base.
• Stand the four equal-sized 2x4s on end and form into a square. Glue ends and screw together.

• Place base on top of saved 36-in. plywood circle and draw around the perimeter with pencil.
• Cut the plywood along line with circular saw. Attach square plywood piece to base with glue and screws. Flip over.
• Attach the 34-inch 2×4 vertically at back of base, centered, short side against the back.

Make and attach cross braces

Cross braces should be beveled (angled on the face of the board) to support the upright. Forty-five degree angles are a good choice.

• Measure the distance from the side of the upright 2×4 to the side wall of base.
• Divide the distance by 0.707, the cosine of a 45-degree angle.
• Cut the cross braces at this length, beveling both ends 45 degrees with a miter saw.
• Fit cross braces between upright 2×4 and base, glue and attach with screws.

Make plywood support

• Cut a roughly 6-in. by 6-in. or larger square of plywood for extra support in the center of the wheel.
• Using a Speed square, draw bisecting perpendicular lines through the center all the way to the edges.
• Trim with jigsaw to make it cat-shaped (or any shape you want), or keep as a square.

• Hold the caster backing centered on the pencil lines and draw the four bolt holes onto the plywood.
• Drill out the holes with a 3/8-in. bit.
• Center cutout on wheel backing and trace bolt holes onto plywood. Drill out holes.

Prepare upright

• Disassemble caster and remove wheel. Keep the bolt and nut.
• Fit caster snugly on vertical 2×4 two inches from the top and mark bolt holes. Remove.
• Drill hole straight through marks on 2×4 with a 1/2-in. drill bit.
• Attach caster with reserved bolt and nut.
• Attach 5/8-in. roller ball bearing 18 to 20 inches below the caster to provide wheel support and reduce friction.

Attach wheel to base

• Place wheel upright on ground. Grab a helper for the next steps.
• Lift wheel and slide one bolt with washer through plywood into corresponding bolt hole on caster. Add a washer and spin on a nut.
• Have your helper support the wheel while you add the rest of the hardware.

• Tighten all bolts and nuts with a nut driver and tongue-and-groove pliers or two sets of pliers.
• Spin the wheel to verify it works. If needed, cut bolts flush with a hacksaw.

• Add hook and eye to the back of wheel and base to prevent it from moving when needed.

Paint

• Paint plywood, dowels and base, or leave as natural wood.
• If using spray paint, do it in a well-ventilated garage or outside. You don’t want your cat-themed DIY to make you or your family sick.
  • Cover plants and structures nearby to spare from overspray.

Add carpet runner

• Your DIY cat furniture isn’t complete without a carper runner
• Cut carpet runner 1-in. wider than running platform.
• Roll up and fit inside wheel. Line up visible edge flush with wheel.

• Add carpet tape or glue. Unroll and press carpet to dowels, keeping edge flush.
• Fold front edge up onto inside of wheel as you go.
• Staple front edge of carpet to inside front side of wheel.

Add turf and finishes

• Finish base, if not painted, with turf or carpet.
• Glue or staple turf or carpet to outside edge of wheel.

• Cover the center cutout with turf, add scratchers or otherwise decorate as you see fit.

• Lure your cat onto the wheel and hope for the best.