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DIY Refillable Notepad with Chicago Screws: Dual-Section Notepad Tutorial

Finished dual-section DIY refillable notepad bound with four Chicago screws
Finished dual-section DIY refillable notepad bound with four Chicago screws

Two independently bound notepad sections in one body — three chipboard covers and four Chicago screws, so you can refill either half without touching the other.

Two notepads sharing one body. Three chipboard covers — front, middle divider, back — held by two separate pairs of Chicago screws, so each section binds independently. Refill the work side without disturbing the shopping list on the other.

These tutorials use Planify Pro, a drag-and-drop tool for designing printable planners and stationery. Building and editing is free — exporting a PDF needs a plan, from $9.99/month.

Get the template

Open it in Planify Pro to change the size, colours or artwork before printing — or print it exactly as it is.

Export and print

Inserts: Save/Export → Single Pages → Paper → A4 → Generate PDF.

Cover: Save/Export → Selected Page → Paper → A4 → Generate PDF. Print the cover at 125% scale — that's the margin you need to wrap the chipboard edges.

Print from Adobe Acrobat Reader. The two sections can use completely different insert designs; nothing about the build requires them to match.

What You'll Need

Sheets of 1.4mm chipboard for the three notepad coversChipboard 1.4mm Ream of 70gsm paper for the two sets of notepad pagesPaper 70gsm+ White glossy sticker paper for wrapping the chipboard coversGlossy Sticker Paper
Chicago screws in 20mm length for the two binding pointsChicago Screws 20mm Single hole puncher for the pages and chipboard coversSingle Hole Puncher Heavy duty guillotine paper cutter for the pages and chipboardGuillotine Paper Cutter

You'll also want a screwdriver — Chicago screws tighten by hand, but a screwdriver gets them properly snug without chewing your thumbnail.

Instructions

1. Print and cut both sets of pages. Trim on the guillotine. Keep the two sets separate — they're bound at different points and won't be interchangeable once punched.

Printed notepad pages being trimmed to size on a guillotine cutter

2. Punch the pages at the top. Small batches, all registered to the same edge. One misaligned batch and the screws won't pass through.

Notepad pages being hole punched along the top edge

3. Cut the three chipboards. 1) 15 × 11 cm · 2) 11 × 2 cm · 3) 11 × 2 cm. The big one is the backing board; the two narrow strips are the clamps that hold each section down.

One large chipboard backing board and two narrow chipboard strips cut to size

4. Print the cover at 125% and cut out both pieces. One large piece for the backing board, one to be subdivided for the strips.

Cover design printed at 125 percent and cut into two pieces

5. Wrap the large chipboard. Peel the backing, centre the board on the adhesive, and check it's square before pressing anything down.

Large chipboard backing board placed onto the printed sticker cover

6. Trim the corners. Angled cuts at each corner so the folded margins meet instead of overlapping into a bump.

Corners of the sticker cover being trimmed at an angle

7. Fold all the sides in. Press firmly along the whole length of each fold.

Sticker margins folded over the edges of the backing board

8. Cut the second cover piece into two. Each part needs to be big enough to wrap a 11 × 2 cm strip with margin to spare — cut generously, you can trim after.

Second cover sheet being cut into two smaller wrapping pieces

9. Wrap both narrow strips. Same method — these are fiddly because they're thin, so fold the long sides first and pull the paper taut as you go.

Two narrow chipboard strips being wrapped in printed sticker paper

10. Line the insides. White glossy sticker paper over the folded edges on all three pieces.

White glossy sticker paper applied to the inside of the chipboard pieces

11. Punch the backing board. Two holes for the first section, at the top. Use a punched page as the template.

Backing board being hole punched at the top for the first binding point

12. Punch the first narrow strip. Match it to the backing board — hold them together and mark through rather than measuring twice.

Narrow chipboard strip being hole punched to match the backing board

13. Get four Chicago screws. Two pairs — one pair per section. Separate the posts from the screws before you start assembling.

Four Chicago screws laid out ready for the two binding points

14. Push the posts through the backing board. From the back, so they stand up through the front face.

Chicago screw posts pushed through the backing board from behind

15. Thread the first set of pages on. All of them at once — you can't add pages later without unscrewing.

First set of notepad pages threaded onto the upright screw posts

16. Add the first narrow strip. It goes over the pages as a clamp — this is what holds the section down and gives it a finished edge.

Narrow chipboard strip placed over the pages onto the screw posts

17. Screw the first section closed. Snug, not forced — over-tightening strips the thread and the notepad stops being refillable.

Chicago screws being tightened to close the first notepad section

18. Mark where the second section goes. Lay the second set of pages in position on the board and mark through their holes. Marking from the actual pages beats measuring — it accounts for however the first section sits.

Position of the second set of inserts being marked on the backing board

19. Punch the second set of holes. Single hole puncher, on the marks. Take your time — the board is already finished, so a misplaced hole shows.

Second pair of holes being punched in the backing board with a single hole punch

20. Fit the second pair of screws. Posts through from the back, same as before.

Second pair of Chicago screw posts inserted through the backing board

21. Load the second section. Pages on, then the third chipboard strip over the top.

Second set of pages and the third chipboard strip fitted onto the posts

22. Screw it closed. Same snug tightness as the first section.

Second pair of Chicago screws being tightened closed

Two sections, two binding points, one pad — and either half refills on its own.

Finished dual-section refillable notepad with both sections bound

Troubleshooting

The second set of holes doesn't line up. They were measured rather than marked through the actual pages. Once the first section is screwed down it sets the geometry for the second — work from it, not from a ruler.

Pages won't sit flat under the clamp strip. The strip is punched slightly off from the board. Hold the two together and mark through before punching, every time.

The screws bottom out before the strip is tight. Too many pages for 20mm screws. Remove a few sheets or move up a screw length — don't force it.

The narrow strips look untidy. Thin pieces are the hardest to wrap. Fold the long edges first, keep the paper under tension, and trim the excess before the last fold rather than after.

Selling these

Two sections in one pad reads as a considered product rather than a craft item, and that's a pricing argument. Buyers understand why it costs more than a single notepad because they can see two of everything.

Pair the sections thematically in your listings — meals and shopping, work and personal, to-do and notes. A named pairing sells better than "dual-section notepad", because it tells someone what it's for.

And as with any refillable format, insert packs are the follow-on sale. Sell the pad once and the paper repeatedly.

See 20 profitable planner niches and how to price bundles for more on selling these.

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