How to router Genesis slotted handle?

crosseyedphoto · September 18, 2018, 08:26:11 PM

I see many of you on here with the Genesis slotted handle and was wondering if any wood workers could chime in with any tips on how to make this? I have a router (fixed and plunge) so I want to take a stab at making my own. Are you guys using a 1/2" wide bit for the slots and a chamfer bit to chamfer the edges? I don't have a router table so I'm trying to brainstorm how to make a jig to get it done. Any tips or size dimensions would be greatly appreciated! Thanks!

Note: Screenshot was taken from a Genesis that @SixZeroFour had restored.

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56MPG · September 19, 2018, 01:35:05 AM

Page 4 in this thread shows the jig I built to do this. The Jr has only two slots, but the jig can do 3 with a couple adjustments. I plunge cut halfway through for each slot, then flipped the handle in the jig to finish the slot, then switched to a chamfer bit. Could use a quarter round bit, but I did not have a small one at the time.

http://weberkettleclub.com/forums/weber-gas-grills-electric-cookers/genesis-junior-restore/45/

Have fun!

crosseyedphoto · September 19, 2018, 03:29:28 AM

@56MPG Dude! Great idea! Thanks!

MacEggs · September 20, 2018, 09:12:47 AM

Marty's ( @56MPG 's) junior restore is truly inspiring.

@crosseyedphoto , be sure to post what you end up with.

crosseyedphoto · September 20, 2018, 09:44:51 AM

Just need to add wood for the start and stop and she'll be ready to go!

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JEBIV · September 20, 2018, 10:01:13 AM

Quote from: crosseyedphoto on September 20, 2018, 09:44:51 AM
Just need to add wood for the start and stop and she'll be ready to go!

It appears success is right around the routed corner !!

crosseyedphoto · September 20, 2018, 10:33:56 AM

LOL!

crosseyedphoto · September 23, 2018, 07:04:45 PM

Thanks again for the jig advice @56MPG It turned out perfect! Ready to stain...

56MPG · September 24, 2018, 04:01:31 AM

Nice! Need to make a three-holer myself for an upcoming Restore.

crosseyedphoto · September 24, 2018, 08:21:51 AM

Done! Went with a colonial maple stain and sealed it with a spar urethane.

inkaddictedchef1 · September 24, 2018, 10:34:46 AM

Beautiful

Sent from my SM-G965U using Weber Kettle Club mobile app

RottiGuy · September 24, 2018, 12:09:16 PM

Grate Job!!

Sent from my SM-G950W using Weber Kettle Club mobile app

JEBIV · September 25, 2018, 03:22:36 AM

Ah success !!

db130 · September 26, 2018, 12:20:47 PM

@crosseyedphoto, any interest in making more?

crosseyedphoto · September 26, 2018, 04:26:39 PM

Quote from: db130 on September 26, 2018, 12:20:47 PM
@crosseyedphoto, any interest in making more?

@db130 Sure! Shoot me a PM.

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How to router Genesis slotted handle?