Making Handles Continued I left a small amount of clearance between the jaws and
the step in my work piece. The reason is because the square area is just
over 2" long, and I want my handle to be right at 2". This gives me just
enough room to cut off the part without any clearance problems.
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As you can see, the handle is now one inch
diameter along with a full radius on the end. So far so good.
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I adjusted my compound to 10 degrees and cut the angle.
I also took time to sand while I was here, ending with 320 grit paper.
Notice my parting tool is not all the way through yet. I stopped short
because I don't want the handle getting damaged once it cuts through
when things are spinning.
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I placed my saw against the step and carefully sawed the handle off.
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Here is what's left of the excess handles. The wooden
dowels worked great so I could clamp on my parts nice and tight. Also
note the small distance I had leftover so when I cut through, the wood
dowel wasn't in my work piece so it worked like I wanted.
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A small amount of hand sanding with my sanding block made quick work of
the rough sawcut surfaces.
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Router Table
I wanted the pockets to have a nice smooth entry so I used my router
table with a 1/8" roundover bit on each pocket.
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I also want to put a radius on all the outside surfaces. The
corners will have a 1/4" radius but the lid will get a 3/16" radius. To
make sure the lid and base line-up, I'm using my surface plate to lay
them flat, then I can clamp them together making sure they both line up.
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And there we go, 1/4" radius at the four corners and 3/16" around the top.
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Assembly
I'm using a steel dowel pin to hold the handle on with, and it will also
be used so the lid can pivot. The pin is 1 1/2" long.
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