Router pattern for handles?

[mloretitsch]

Bill, I am admiring your cut in handles on the T48 and am contemplating different shape handles. How did you make the pattern? Just wing it by hand?

I have a top bearing pattern bit that would work nicely, but it's tough to create the first pattern cleanly.

Thanks for any advice!
-Matt

[Bill Fitzmaurice]

I drilled two 1-1/2" holes spaced four inches apart and then cut away the space between them. I used oak for the pattern, it will last through many cabs.

[bgavin]

The Harbor Freight forstner bit set is excellent for the money. I use 'em in my drill press to cut brace holes.

Thanks for the tip on the router jig for the handle holes.

[Tom]

Cheap, jagged Forstner bits are the ticket. I used one of my nicer hardwood Forstner woodworking bits on plywood, and now it is nearly unusable from cutting through that silica-filled plywood glue.

I guess it is like cutting sand!

[Robert]

Here is my tip for making a handle (or anything else) template.

Get a piece of board half inch thick that is probably 3 or 4 inches wider and longer than the cutout you want to make.
Draw on it (in the centre) the outline of the cutout.
I then use half inch wide strips screwed to the board as a sort of outline of the drawn shape.
Drill a starter hole in the board somewhere inside the area to be cut out. It helps if it is closer to the edge and the hole needs to be larger than the diameter of your router bit.
Set up your router on a router table and route around the half inch pieces using a guide bit.
Remove the half inch strips and screws and you have a perfect hole jig.

To use, just screw it down where you want the cutout and route away with the guide bit.

I also have made jigs like this for piezos and speakers. I bit of work to set up but saves time during builds rather than using a jigsaw

[Christian]

Get a piece of board half inch thick that is probably 3 or 4 inches wider and longer than the cutout you want to make.
Draw on it (in the centre) the outline of the cutout.
I then use half inch wide strips screwed to the board as a sort of outline of the drawn shape.
Drill a starter hole in the board somewhere inside the area to be cut out. It helps if it is closer to the edge and the hole needs to be larger than the diameter of your router bit.
Set up your router on a router table and route around the half inch pieces using a guide bit.
Remove the half inch strips and screws and you have a perfect hole jig.

Bingo! I do this as well and whatever time is lost in creating the template is more than made up for in production. Good tip!

I also suggest using something besides plywood as the template, as it gets beat up pretty quick.