Tap handle

Instructions

I laminated three pieces of wood to add some contrast, but a single block would work. Step one: cut the pilot hole for the 3/8-16 threaded insert on the end of the block. The brand I used (E-Z Knife) calls for a 33/64ths pilot hole (not 1/2, nosiree). Step two: cut the lettering for the diamond inlay, then make the outside cut for the diamond inlay (eventually using zero offset). I used 1/2 inch maple for my diamond inlay. Step 3: cut the pocket for the diamond inlay. I did this while the block was still rectangular to make it easier to use a grid to place the diamond. I made the inlay 1/4 inch deep for a 1/2 inch thick diamond, so it sits proud as shown in the pic. I used the 16mm bit to pocket (its awesome), followed by a 1/4 bit and finally a 1/16 bit (for sharper corners). I also used the 1/16th bit to add a negative offset that ended up at .003 (sneak up on it by test fitting the diamond). The 1/16th bit made the corners sharp enough to fit the diamond without chiseling, but I suppose that will vary based on the wood used. Step 4: The handles are tapered, though you could just leave them square and be done. I made a template using Origin (sort of looks like the shape of a a coffin in the pic). Then used the template to cut the handles to final size on a table saw using an L fence. (Obviously cut the handles to size before gluing in the diamond inlays.) There are other options to cut the tapers: You could use Origin to cut them directly on the handles, or you could use the template with a band saw and/or router table. To add more contrast, I'm going to stain the handle before gluing in the light colored diamond. I'll probably also use some fill for the lettering (turquoise or epoxy, probably)