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If you need a pull that's easier to grip, this hefty oak dowel pull is the answer. Here, you have two different parts to make — the rounded end brackets and the "tenoned" dowel that's glued in between The brackets are made in pairs from a thick blank, as shown in the upper and middle drawings. This way, they'll turn out identical. You'll want to
round the ends of the brackets on the band saw before drilling the holes for the tenons and finally cutting the brackets to size.
The tenons on the ends of the dowel are made by rotating the dowe! over the table saw blade. An auxiliary fence attached to the miter gauge acts as a back support while the rip fence is the end stop. I left the tenons a hair oversize and sanded them to fit.
A length of l"-dia. dowel and a jj? %"-dia. core box bit will allow you to
make a bunch of these finger pulls in short order. The router table setup I used is shown in the left drawing below. A V-block and the miter gauge are used to feed the dowel over the raised bit and create a groove on each side. Then you move to the table saw, cut the pull loose, and repeat the process. You'll want to check out the box below to mount these pulls.
Making this wood and aluminum pull starts by cutting a 4"Tong section of 1 "-square aluminum angle and buffing it out. The next step is to drill and countersink a pair of mounting holes for some woodscrews in one face of the angle (upper drawing).
The %"-dia. dowel that provides a grip is kerfed to fit over the angle. The lower drawing shows how a block with a "stopped" hole holds the dowel while you run it through the saw. Finish up by gluing the dowel in place with epoxy. A
Easy Mounting With:
Many pulls can be installed with ordinary woodscrews. But sometimes this isn't the best option. The problem is that a woodscrew won't hold well in end grain or can split a pull with a small mounting surface. The pulls in the photo are good examples. And as you see, the solution is to add threaded inserts to the pulls and use machine screws.
You'll find that press-in inserts are the easiest to install and still provide plenty of grip. Two types are shown at right. Both require a hole less than V4" in diameter.
To use with the inserts, you'll need 8-32 thread pull screws (top). If you're not sure of the length you need, try the one-size-fits-all "break away" screws (bottom).
Split fin-type insert
Standard 8-32 pull screw
Screw can be snapped off at gaps