The front door is the first thing everyone sees when they enter.
What better way to blow away your guests than having your own super cool custom door handle!
In this note I will take you through the process of designing, making and installing your own wooden door
These special handles were commissioned by local taekwondo athletes.
Dojang in Cape Town.
The handle is functional but not mechanical in nature.
Keep in mind that this Instructure just provides a guide.
One must have creative freedom!
Adjust and add spice at any time.
We would also like to thank you very much for your suggestions on a better approach.
Material: Tools: This section will give a brief introduction to how to digitize the handle of your choice.
Later, I printed and cropped the designs and traced them back to the wood, outlining where I had to cut.
Maybe you don\'t even need to create a digital file that you designed.
Since this project is designed for the customer, I need to do a digital design so I can generate some rendering for the customer for evaluation.
Having digital files also allows the use of CNC machining or laser cutting, etc.
Please feel free to skip this section if you have completed the design.
For this project, I created digital drawings and render drawings using Blender.
First, start with an image similar to the symbol you want to recreate.
This may be an existing design, or it may be the one you draw.
Import this image into blender as a background image.
Instead of adding a plane by pressing Shift a and hovering over the grid, then selecting the plane.
This yields a plane with 4 vertices.
Press Tab to enter edit mode.
By right-clicking, while holding down the Shift key, select 3 of the 4 vertices, Press x, and press Enter to delete them.
This left us a peak.
Select the vertex by right-clicking the vertex and pressing \"g\" to adjust its position relative to the background image.
After the vertex is located on the background image profile, press the \"e\" Key to squeeze out.
Extrusion basically generates another vertex connected to the parent vertex.
When the second vertex is on the outline of the background image, left click.
Repeat this extrusion process until we get the outline of the image.
Note that to connect the last vertex to the first vertex, select two, press Ctrl v, then click merge, and then click center \".
This will merge the two vertices into one, thus closing the shape.
To fill the shape, select all the vertices in edit mode by pressing \"a\" and press \"Alt f\" of the autofill face \".
You can then squeeze out the 2D shape by pressing \"e.
Now we have the 3D model we designed.
This can be used for rendering as well as for CNC etc.
You can export it as an STL file and then open it in slicerforFusion360, where it can be exported as a pdf for printing or processing.
This pdf can then be printed and used to track the shape to the wood for cutting.
This is just a brief explanation of how to do a simple design in Blender.
The internet is full of amazing design resources.
I highly recommend exploring.
Once we print and crop the patterns, trace them back to the wood.
This will serve as a guideline when cutting wood with a reel saw.
Get ready, put on your safety glasses and slowly start cutting along this thread.
Note: it is generally not recommended to cut such thick hard wood on the reel saw.
So please make sure not to apply too much pressure when cutting as this can cause the blade to be damaged or broken.
Alternatively, you can make the handle with thinner wood, and you can stack the wood together to get the required thickness.
This process can also be replaced by a CNC machine.
For more information, check out the customutables CNC class.
If you are not familiar with using a rolling saw, check the link below for some advice: All parts are cut off and it\'s time to smooth them out.
Check all parts using a sander or sandpaper, especially focus on checking if the edges are smooth.
Start with a rougher sandpaper and move to a finer sandpaper until it is not possible to cut someone\'s sharp edge.
Make sure the parts are free of dust.
Shake and stir the wood sealant or paint before use.
Thoroughly apply the first layer of paint to the wooden components.
Please note that the wood acts as a sponge when applying the first layer of paint, so several layers must be applied.
Once the first layer of paint is dry, you have to gently polish the parts again with fine sandpaper.
I put on another coat and waited for it to dry and then sandpaper again.
Then I applied for the last two coats.
My client later decided that the handles were black and gray, so I polished them and added some black and gray wood paint.
Now that the handles are ready for installation, we have to mark where we are going to connect them.
Please consider any keyholes or locking mechanism when deciding the location.
I put my hand on the door and marked with a pencil where I needed to drill holes.
As you will see in the next step, each handle is connected to the door by two round wooden spacers.
When placing the handle, try to make the spacer as close as possible to the center of mass of the handle.
This will make the handle stronger.
After marking placement, create a pilot hole with a 3mm bit.
Then use the 6mm bit to increase the hole size.
Finally, the countersunk bit is used to sink the head from the inside so that the screw is flush with the door.
Next, we will drill the guide hole on the handle.
I put the handle on the drilled door frame and pass the screw across the other side so that there is a visible mark on the handle indicating where I need to drill.
I put some masking tape on the 3mm bit to prevent me from drilling through the handle.
You want the hole to go through about half of the wood I. e.
There should be a minimum of 10mm between the surface and the end of the hole.
Guide holes are necessary to prevent wood cracking.
After the hole is completed, add some wood glue to the wooden gasket, and then screw the handle in place.
You should tighten the screws at the end manually.
You don\'t want it to be too tight because it will crack the wood.
Make sure to wipe off any dripping wood glue.
Finally, you can cover the hole from the inside by placing a plastic cover on the hole, or by covering the hole with some filler.
You can then paint it to match the door.
The final stage of this project is the installation center symbol.
I followed the same procedure as outlined in the previous step.
On top of that, I used a couple of washers to separate the symbol from the door instead of a wooden gasket.
I had to cut the screws with my Dremel because the screws were too long.
Also note that I can cut the symbol in half (
So it won\'t stand out)
But my client and I decided that it would be more beautiful to be a single item because of the finer details.
Anyway, only the door with the logo will be opened so that there is no fear of another door touching the prominent logo.
This is all the people!
We made some really cool custom door handles and will definitely make some memorable first impressions.
I hope you enjoyed the instructions!
Please feel free to comment and provide feedback.
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