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The first thing we need is a routing pattern and a pattern
making router bit. First on a 3/4" piece of plywood I measure in from the
side to the center of where I want the handle to be. Next I measure down
from the top to the center again. I was 6" from the side and 3-3/4" down
from the top. Now center the pull on these lines and trace around the inset
part of the pull. Cut out the hole very carefully and sand smooth, your
router bit will be following the inside of this hole to form the mortise
in your drawer front, so be as accurate as possible! |
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Because I only have 020" of an inch between the back
of the handle and the inside of the drawer, I figured I'd need to find
a way to give me a little more clearance, or "fudge factor". I decided
to see if I could sand away a little off the bottom of these pulls.
First I measured the overall thickness of the wooden
pulls. I'm using a set of Dial
Calipers, this is the most accurate way to measure thickness and depth
of stock. Before sanding I have .610" |
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Now I check the inside of the pull: .545" That
leaves .065" of wood at the bottom. On my 12" sander I careful remove about
.025" of the back side of the pull leaving .040" thickness. This makes
my minimum mortise depth about .415". |
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Now on a scrap of wood the same thickness of my drawers,
I start cutting sample mortises using the jig I made earlier. The one on
the right fit fine but left the bottom awful thin. I went with the middle
mortise of .425" depth. this left me a .010 gap between the bottom of the
mortise and the back of the handle, and .040" thickness left in the drawer
front. |
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Now for the fun part! I took my pattern and flushed it
to the top of the drawer and the side, and secured it with a couple of
clamps. |
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Now start up your router and carefully plunge it into
your drawer. clean out the middle part then follow around the pattern in
a clockwise direction. Shut off the router and wait for it to stop before
pulling it out. You don't want to damage your pattern by nicking it! |
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Now flip over your pattern, flush it to the top and the
other side, and route out the other handle. Using this method ensures your
handles are equal distance from the sides and top, and that each drawer
will be the same. But in the case of my drawers, the lower ones were deeper.
No problem, just flush the sides and measure down from the top for your
desired distance from the top. |
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Pop in the handles and they look real good! |
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Now to set them in the drawer forever, use a little slow
set epoxy. They'll be very secure, and if a little squeezes out it
will blend in with the finish! |
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You don't need much clamping pressure, just enough so
they don't fall out before the glue dries. |
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You can find
these wooden pulls here. |
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And this is the patter making bit, you can find
them here.
Notice that the bearing is above the cutter, not below.
This is a very handy little bit for your collection! I find the 3/8"x1"
takes care of most of my needs. |
