Making wooden drawer pulls
At left, the workbench drawers I built in 2008. I wanted something like that again, but I was thinking I could make them a bit flatter. I have never had problems using the shallower handles on my tool stand, and I also like the elegant handles I used for this dresser.
So the pattern for my new handles has the same size opening. The front part is much shallower than my previous wooden handles because I figure that part, being along the grain is not going to break anyway.
But I'm not sure that was such a good idea, because clearing a space to turn the corners with the bandsaw was difficult, especially because the ironwood is very hard and my bandsaw blade is in need of sharpening.
I wasn't sure at first how to trim the inside of the handles to be straight and smooth. A router seems the ideal tool for this job, and a router mounted in a slot mortiser is even better.
It occurred to me that the right kind of template on the pantorouter would have allowed me to cut these insides in one setup. But I only needed eight handles, so it wasn't worth getting too complicated.
I marked the outside round using a round object. Its the rotor from an oscillating fan motor that I destroyed in this video.
But routing the outside required a different sort of jig, two pieces of 1/4" plywood, with a handle shaped cutout on the edge, squeeze the handles together for routing the outside. In retrospect, I could have used that setup to route the inside edges as well.
I carefully drilled two holes in an extra piece of ironwood that was the same length and width as the handles. I then clamped that to each handle to drill the holes in the handles. I set the depth stop on the drill press to drill almost all the way through.
I made a drill guide for drilling the drawers as well. It's a piece of 2x4 with a rabbet cut along the side so I can hook it over the front of the drawer to get the vertical position just right. I drilled the holes in this guide using the same block that I used as a drill guide for the handle holes. That way, if a hole is off by a fraction of a millimeter, the holes in the drawers will be off by the same amount and the handles still end up horizontal.
I cut another scrap of wood to hook onto the edge of the drawer to line it up horizontally each time.
Making drawer pulls (2009)
Workbench drawers (2008)
Recessed drawer knobs (2012)
To my Woodworking website