This is my simple quick way of making knobs. I cut out a round with a hole saw in my drill press. Then ... (see photo collage from Left to right, top to bottom)
* I use a hex bolt and chisel out a recess. Then tap in the hex head into the recess so the underside sits flush to knob's bottom. After checking the fit, I remove and epoxy in the bolt.
* Next I plug the hole left by the hole saw.
* Then I flush saw off any protruding dowel.
* Next, I clean up with a chisel.
* After the epoxy has dried, I chuck up the assembled knob in my drill press and smooth out with a rasp.
* While still in the drill press, I smooth it with various sandpaper and it's ready.
I do something similar but before using the hole saw, I often cut 3, 4 or even more smaller holes, depending upon the size and shape desired, around the perimeter to create notched knobs. Handy when you need a little more grip. 3 larger holes will give you sort of a 3 wing knob and 5 or more small holes give you one sort of with detentes around the perimeter.
--Nathan, TX. Hire the lazy man. He may not do as much work but that's because he will find a better way.
By the way, here is a little pro tip that I picked somewhere online when using a hole saw in general. A couple of relief holes around the perimeter (waste side) of where the hole saw is cutting will often result in cleaner holes and easier cutting. If you are cutting for a hole, the relief holes are just inside the perimeter. If cutting disks, just outside. You want the relief hole to just make contact with the waste side of the cut. The bigger the hole saw the more relief hole to pre-drill. Usually 1 to 3 1/4" holes are enough. Since hole saws do not pull saw dust out of the kerf very well, especially on really thick pieces, the hole gives the saw dust a place to go and makes for cleaner cuts with less chance of burning or just overheating the hole saw which can ruin them. I have found that the cuts go twice a fast when I take the time to do this.
--Nathan, TX. Hire the lazy man. He may not do as much work but that's because he will find a better way.
Lazyman I do something similar but before using the hole saw, I often cut 3, 4 or even more smaller holes, depending upon the size and shape desired, around the perimeter to create notched knobs. Handy when you need a little more grip. 3 larger holes will give you sort of a 3 wing knob and 5 or more small holes give you one sort of with detentes around the perimeter.
Lazyman ... I do that too. I make many kinds of knobs. I have a few step and repeat jigs I made as well. This is just a quick and simple way that actually functions well.
