The Tool Desk
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Make the wooden replacement knob from 3/4 × 4 × 4-inch stock, four edge grip recesses, and a glued-on stem. Dennis O’Leary’s WOOD Magazine design uses scrap birch and a 3/8-inch T-nut; check your jig’s hardware and dimensions before building, because the published design is not confirmed to fit every model.
Materials and tools
O’Leary’s project was published by WOOD Magazine on May 8, 2017. He says he used scrap birch after he could not find a local supplier for the plastic knobs. The specified blank is 3/4 × 4 × 4 inches, so suitable scrap can work without buying new lumber.
- 3/4 × 4 × 4-inch wood blank
- 3/8-inch T-nut
- Drill and 1-inch Forstner bit
- Circle cutter set to 1 1/2 inches
- 1-inch plug cutter
- 7/16-inch drill bit
- Glue for the knob and stem; the drawing specifies epoxy for the T-nut
How to make the knob
- Lay out the blank. Mark vertical and horizontal centerlines on the 3/4 × 4 × 4-inch stock.
- Drill the center recess. At the intersection of the lines, drill 1/4 inch deep with a 1-inch Forstner bit.
- Add the grip recesses. With the same bit, drill four recesses at the 3, 6, 9, and 12 o’clock positions. Space each recess center 1 3/8 inches from the center of the blank.
- Cut out the knob body. Set the circle cutter to 1 1/2 inches and cut the round body free.
- Make and attach the stem. Use a 1-inch plug cutter on the remaining stock to cut a 1-inch stem, then glue the stem to the knob.
- Drill for the insert. Drill a 7/16-inch hole through the assembled knob and stem to accommodate the 3/8-inch T-nut. The source drawing specifies epoxying the T-nut into the hole.
Check the fit before adapting the design
The dimensions above are the published design, not a universal tenoning-jig specification. Compare the intended jig’s existing knob, stem arrangement, and threaded hardware with the plan before cutting. The source does not establish compatibility across jig models or compare adhesives, so do not assume that the specified fit or attachment will suit a different setup.
O’Leary describes the result as “an attractive knob that you can really get a grip on.” The article does not report measured grip improvement, durability testing, or cost savings.
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