Salt and Pepper Keepers  3                                              05-2019

 

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.
 

 

 

As you can see, the handle is now one inch diameter along with a full radius on the end. So far so good.
 

 

 

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.
 

 

 

I placed my saw against the step and carefully sawed the handle off.
 

 

 

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.
 

 

 

A small amount of hand sanding with my sanding block made quick work of the rough sawcut surfaces.
 

 

 

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.
 

 

 

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.
 

 

 

And there we go, 1/4" radius at the four corners and 3/16" around the top.
 

 

 

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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