Making Jig Knobs... - Router Forums
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post #1 of 39 (permalink) Old 04-15-2012, 06:42 PM Thread Starter
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Default Making Jig Knobs...

Took apart a fan that wasnt working and kept some of the parts...
The screw like plastic knob on the left side was part of it, so I used it as a template to mark
and cut some DIY jig knobs. I then cut out some round dowels from a piece of wood with a hole saw and 1/4 bit installed...sanded them both... I then ran 1/4-20 rod thru both of the pieces of wood to keep them stable then glued them together.
To some of the seasoned veterans this might be corny but for someone starting out in woodworking, hopefully this helps or gives you some ideas!

Next step...finish the rest of them since this was the prototype and cover them with polyurethane...on this process if anyone has a suggestion I would appreciate it.

After making this one I doubt if I will ever buy another knob again

Dask

Edit: The cutouts on the edge were done with a fostner bit and so was the hole in the middle of the knob.
If someone wants detailed pics I can take them and post them also.


Last edited by dask; 04-15-2012 at 07:11 PM.
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post #2 of 39 (permalink) Old 04-15-2012, 09:06 PM
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dask,

I for one would like all the info you have on this as I will add it to my list of how to do,

It was like 4 weeks ago I need to get some of these knobs or make some I did not find anything that I could use to get my brain around or to understand what was going on at that time, any help would be great,

GRLevel3 or Poppa Rob
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post #3 of 39 (permalink) Old 04-15-2012, 09:50 PM
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Hi dask

Plastic dip-it works well you can also get in the spray can..

Amazon.com: Plastic Dip Intl. 18201 Red Plasti-Dip: Home Improvement

Plasti-Dip Multi-Purpose Rubber Coating | A.M. Leonard, Inc.

plasti dip spray black - BuyCheapr.com

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Quote:
Originally Posted by dask View Post
Took apart a fan that wasnt working and kept some of the parts...
The screw like plastic knob on the left side was part of it, so I used it as a template to mark
and cut some DIY jig knobs. I then cut out some round dowels from a piece of wood with a hole saw and 1/4 bit installed...sanded them both... I then ran 1/4-20 rod thru both of the pieces of wood to keep them stable then glued them together.
To some of the seasoned veterans this might be corny but for someone starting out in woodworking, hopefully this helps or gives you some ideas!

Next step...finish the rest of them since this was the prototype and cover them with polyurethane...on this process if anyone has a suggestion I would appreciate it.

After making this one I doubt if I will ever buy another knob again

Dask

Edit: The cutouts on the edge were done with a fostner bit and so was the hole in the middle of the knob.
If someone wants detailed pics I can take them and post them also.




"It's fine to disagree with other members as long as you respect their opinions"

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post #4 of 39 (permalink) Old 04-15-2012, 09:55 PM Thread Starter
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Quote:
Originally Posted by GRLevel3 View Post
dask,

I for one would like all the info you have on this as I will add it to my list of how to do,

It was like 4 weeks ago I need to get some of these knobs or make some I did not find anything that I could use to get my brain around or to understand what was going on at that time, any help would be great,

GRLevel3 or Poppa Rob
Rob...I will go take the pics and post them in details...if not tonight, I will have them up by tomorrow.

Dask
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post #5 of 39 (permalink) Old 04-15-2012, 10:34 PM Thread Starter
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Rob,
I didnt set up all the Fostner drill on the drill press and Im hoping my descriptions will be good enough...if not ask for better details.

First, I trace the knob template unto a piece of wood...




I then draw 3 lines from each of the 6 points that you see on the knob to find the center point.




I then use a 1/2 fostner bit to cut out where the 1/4-20 nut will fit into.




The next step is to use a hole saw to cut out knob. By keeping your piece secured to the drill press you are guaranteed that the hole for the nut and the outer cut will line up perfectly.



I then attach a fostner bit that will have the same radius as the knob, I secure the knob and drill out each section. This part takes some time since each time you have to release how you secure the nut to the drill press so you can rotate and align for the next cut...I use hold down clamps.




From smaller stock cut out part that will attach to the opposite side.




I used a drum sander on my drill press to sand the knobs before I glued them...also, to make sure the holes line up. run a 1/4 bolt thru the knob and the round piece to make sure they are aligned properly when glued.
If these details are not enough, I can take pics of the entire process tomorrow in better detail.

Last edited by dask; 04-15-2012 at 11:23 PM.
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post #6 of 39 (permalink) Old 04-16-2012, 01:21 PM
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Very nice job.
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post #7 of 39 (permalink) Old 04-16-2012, 02:19 PM
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another thing i do is to embed the t-nut in the middle like this. for 1/4-20 bolts, the t-nut and dowel are 3/4" and the holes in the wood are 5/16". it is glued together with some 3M wood/metal glue
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Last edited by Chris Curl; 04-17-2012 at 01:00 AM.
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post #8 of 39 (permalink) Old 04-16-2012, 03:05 PM
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A thought I had. A person might consider using larger size blanks. The already used cross lines could be used to establish lines dividing the segments in half and extending past the outline of the knob. A distance could be set on those lines for the center point of the bit and then drilled. (I think that would be easier than just drilling out that small segment). Lastly the hole saw could be used to size the knob and the material that remains in the hole saw will also be easier to remove. Just I thought I had while reading your process. I don't need any knobs at this time so I have no need to try out my idea.
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post #9 of 39 (permalink) Old 04-16-2012, 03:31 PM
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this template could be used with a 1 foot piece of 1x6 to make 30 or so knobs. they are all 1 1/2" circles for a drill press hole saw. you get 2 types of knobs ... 6 points and 3 sided ones. just stick it to the wood with a glue stick or something and have at it
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Last edited by Chris Curl; 04-17-2012 at 09:02 AM. Reason: more info
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post #10 of 39 (permalink) Old 04-16-2012, 05:01 PM
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Hi Chris

Have you tried your template out ?

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Originally Posted by Chris Curl View Post
this template could be used with a 1 foot piece of 1x6 to make 30 or so knobs



"It's fine to disagree with other members as long as you respect their opinions"

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