Tape Dispenser Recycled for Use With Large Packing Tape Rolls (from Scrap)

I bought a 3000-foot roll of packing tape at a clearance sale, but quickly realized that it would be very awkward to use without some kind of dispenser. I had an old dispenser sized for 60-yard rolls, and decided to take it apart and use the parts, plus scrap wood and hardware, to make a utilitarian dispenser. Not pretty but works just fine!

• Old tape dispenser. I took it apart before taking this image, sorry.
• 3000-foot roll of tape
• Scrap 3/4" lumber, about 12" square. I used a melamine particleboard shelf that was no longer needed.
• Scrap 1x4" lumber, about two feet long (not shown). Other sizes will work as well.
• Screws: I used screws already available in my shop. Sizes vary depending on the actual dimensions of the wood.
• Drill and bits (not shown)
• Circular saw

Exact size doesn't matter, I just made it large enough for the parts and the tape, with nothing sticking out from the sides of the wood.

Forgot! I had to cover the original marks with masking tape to avoid splintering when sawing the upright. And ended up making the bevels two different sizes; couldn't see the marks well. Oh well, no worries.

The feet could be made from 1x2, 1x3, or whatever. I cut mine 10" long. If using narrower board you may want to use screws and glue.

Feet were attached each with two 3" flat-head screws. The holes in the feet were pre-drilled and countersunk slightly so that the heads wouldn't scratch the surface of the table/desk.

The central roll holder was removed and the metal plate located on the upright, such that when the roll of tape was in place, it did not project beyond the edges of the upright.

Notice that the original holes on this plate were on a slightly-raised section. If the original holes had been used, the screw heads would have projected up far enough to rub against the tape roll. So new holes were drilled in the "lower" section.

Screws used were 3/4" long brass flat head, because I had them. :) Locations for the screws were marked with pencil, and pilot holes drilled. Best to make sure the tips of the screws don't project out the other side of the upright.

If you look at the image in Step 3 you'll see a washer with 1/2" hole at the left. That washer was placed on the spindle you see here, to raise the tape roll just another 1/16" and ensure that the tape wouldn't rub against the screw heads.

The plastic tape carrier was then re-attached to the metal plate.

If you look above at the parts used you'll see that the cutter head has a long plastic flap attached. That was needed for the hand-held dispenser, but not here, so it was removed and the cutting blade re-attached with the original screws. CAREFUL! The cutter blade is SHARP!

The cutting head is laid out so that the back of the tape passes over the black roller. Note that the tape is going to feed from underneath, not over the roller.

Pilot holes were drilled and countersunk slightly with a larger drill bit. I should have used a proper countersink, because once the bit went through the melamine, it had a tendency to "grab" the bit. And suddenly the hole was drilled a quarter inch deep :( No worries though, the 2" screws still held the cutter head just fine.

I had to add a small washer between the upright and the axle of the black roller, otherwise the roller wouldn't rotate.

In the second image you can see that I added a long screw, and the tape runs between that screw and the roller. Its purpose was to prevent the tape from slipping off the cutter and flapping back onto the roll. Trying to find the end of the roll was always a chore, and I didn't want to have to do that any more than necessary.

Actually, the tape usually stays attached to the cutter but I didn't want to take a chance.

All done! Not pretty but it works. Just grab the tape, pull, and yank it against the cutter teeth. Hold onto both ends of the tape before cutting, otherwise the tape will often become a snarled mess.

Questions? Comments? Physical threats? ;-)