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Old 11-20-2013, 09:45 AM
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custom armrest door pulls

I just finished fabricating my armrests from a nice solid piece of hemlock. I'm going to use the Lokar billet door pull cups, but I'm trying to figure out the best way of cutting the recess into the armrest. I'm using the oval cups that sit in the center of the armrest. Using a plunge router with a template for the pulls is the simple answer, but because the armrests are curved, following the radius with a router is not ideal. I'd like to get any ideas from the community here before I proceed. Thanks all!

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Old 11-20-2013, 09:52 AM
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sounds like you will have to go old fashion and use some wood chisels.

https://www.google.com/search?q=wood...&bih=675&dpr=1
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Old 11-20-2013, 12:09 PM
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Do you have pictures? I read what you said. Just trying to understand why a router wouldn't work. Seems like some sort of jig would do it? Or, you could "free hand" it.
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Old 11-20-2013, 01:12 PM
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How about this? Do you have a wooden work bench? If so, attach the armrest to the side of your bench the way you would attach it to the door. As you attach it, use a straight edge to make sure the top of the armrest is flush with the top of the bench. Now you have a solid level surface to stabilized your router. You should have your pattern for the hole already lined out on the armrest.

I would use a 1/2", double flute, straight cut bit, allowing for smoother cut. Preset set your plunge for the desired depth. Ovals are great for freehand work. Start in the center and work your way to the outside shaping into the oval as you get closer to your cut lines. Just remember to keep down pressure on the bench side of you router at all times.

Just an idea. Hope it helps.

Chris
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Old 11-20-2013, 02:41 PM
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Thanks for the ideas guys... Killer - your chisel method was the answer that I was dreading! lol I suck at chisel work! I think attaching it to the bench will work Chris, that's a great idea for keeping things stable while I route it. I'll do a test run to make sure so I don't mess up my hand-crafted armrests. I have a straight 1/2" by 1" top bearing bit, so I think I'll create a little oval jig just to be safe.
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Old 11-20-2013, 03:07 PM
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Glad I could help. Be sure your jig is thick enough to allow the bearing to ride high enough that your 1" bit isn't too deep into your armrest. You could cut a template at one end of a piece of something like a 1"X 12", about ten or twelve inches long. Put it flat on your bench, perpendicular to the edge and slide the template hole over your armrest. If the hole is back a few inches from the end, you have a perfect surface to stabilize your router. Clamp the template board to the bench and you're good to go. It's just a concept. You can adapt it to the way it works best for you.
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Old 11-20-2013, 06:25 PM
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Have any buddies that are into woodworking, or custom woodworking shops in your area that have a laser cutter?
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Old 11-20-2013, 09:07 PM
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^^^^what he said
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Old 11-21-2013, 09:47 AM
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Thanks for the great suggestions guys. I don't know anyone with a laser cutter. I'm not a wood worker, so not really familiar with them, but can they limit the depth of cut to a certain depth? I need a recess that measures about 3 1/2" l x 1" w x 7/8" d. I think I'm going to stick with a little lower tech solution, and set up a jig for the router. Using the edge /top of the bench to keep a square base for the router.
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Old 11-21-2013, 11:49 AM
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I'm sure you'll do fine. Let us know how it comes out.
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Old 11-21-2013, 12:32 PM
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I'm sure you'll do fine. Let us know how it comes out.
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Old 11-25-2013, 09:40 AM
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Success! I used a block to hold the armrest square, built a jig, and used the router to create the pocket. I'm super pleased with the result. I used a jigsaw to cut the slot for the door mounting bracket, which still needs to be trimmed to the proper depth obviously. Thanks for the input guys!
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Old 11-25-2013, 11:19 AM
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Nice looking armrests. What are you going to cover them with? A plunge cut on a table saw would work well for the mounting bracket slot, also a plate joiner.
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Old 11-25-2013, 11:28 AM
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Thanks Dan - I appreciate the compliment. I'm going to cover them with thin closed cell, and leather (no seams). I thought about the table saw, but the cut would have been way longer than I wanted after getting to the proper depth. The jig saw was a little sketchy, but I was able to "roll" it in and it worked out great.
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Old 11-25-2013, 11:37 AM
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They look great! Good job.
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