|Project by MT_Stringer||posted 01-09-2014 06:19 AM||6998 views||21 times favorited||20 comments|
There I was working on my table saw sled. I needed some knobs, but had none…so the MacGyver in me said “make some”. I pulled out my jig hardware parts and started to figure out what all I would need and how to make the knobs.
They aren’t perfectly symmetrical, but they work just fine.
I used some 1/2 inch baltic birch that I had on hand. The only thing I had to buy was some 1/4×20 x 2 inch bolts.
I made a template using Photoshop Elements.
To end up with a compete knob, I had to sorta reverse engineer it. I started by using a 1 inch hole saw to cut out the spacers. I decided to do that first while the plywood was still in a complete piece. Then I used a Forstner bit to create a countersink for the bolt head. Then I drilled out the hand reliefs with a 1 spade bit. Next I cut out the holes with a 2 inch hole saw. Actually, this part of the operation went fairly quick.
I chucked each spacer and then each knob in the drill press using a 1/4 inch bolt that has the head cut off. Each piece got a good sanding.
Then it was just a matter of doing the assembly work. I discovered that my impact driver made it really easy to insert the “t” nuts by simply spinning the bolt to draw down the nut into the spacer.
All four fit perfectly. I am really happy with the outcome. All I need now is a can of professional black spray paint and this is a done deal! :-)
Hope you like.
-- Handcrafted by Mike Henderson - Channelview, Texas