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Wood Kettle Handle & Knob

  • February 12, 2015


Carving with a drill is actually really easy. I used a brad point drill bit, a drum sander, and a carving bar to shape the handles. I really like the idea of partial DIY projects that result in an upgraded and customized object. I am excited to customize more of the stainless steel kitchen items with walnut handles so that they will match even though they are different brands. I use my Hario gooseneck kettle for making pour over coffee. I like everything about it except the plastic handles that it came with. I decided to carve new handles out of a scrap piece of walnut I had using my cordless drill. In addition to brad point drill bits I used a carving bur and a sanding drum. This technique can by used to make all sorts of wood replacement parts.

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  • More Information, Tools, & Materials

    • Project Information

    • Tools Used

    • Materials Used

      • BRAD POINT DRILL BITS
      • CARVING BUR
      • SANDING DRUM
      • SCRAP PIECE OF WALNUT
      • HARIO GOOSENECK KETTLE
      • DANISH OIL
  1. Project Steps

    1. Step: 1

      Trace the handle. I traced the outline of the original handle onto the wood with a pencil. I used a piece of 1-inch thick walnut that I had left over from a previous project.

    2. Step: 2

      Drill holes. I used a 3/16th diameter brad point bit to drill a series of holes around the traced outline. I like brad point bits for this task since their sharp points keep them from slipping when you drill holes right next to each other. I cut out most of the handle but left a small piece of it connected to the large piece of wood so that it would be easier to clamp and sand.

    3. Step: 3

      Carve. I clamped the wood to my worktable and used the carving burr to shape the handle.

    4. Step: 4

      Sand. Once I had the rough shape of the handle I switched to the sanding drum and smoothed down the handle.

    5. Step: 5

      Finish cutting off the handle. Now that the handle was shaped I cut it off from the rest of the wood with the drill. I used a knife to clean up a few drill marks.

    6. Step: 6

      Sand. I used 120 and then 320 grit sandpaper to finish the handle.

    7. Step: 7

      Stain. I finished the walnut with a coat of Danish oil.

    8. Step: 8

      Cut out the top knob. I didn’t like the design of the original knob. It was too close to the stainless steel and my knuckles would bump into the hot kettle when I would try and remove the lid. I drew a completely new profile for the wooden knob and then cut it out with the drill.

    9. Step: 9

      Carve and sand. I carved and finished the knob the same way as the handle.

    10. Step: 10

      Remove plastic handles. I drilled a series of small holes through the plastic handle and then used wire cutters to clip away the plastic between the holes.

    11. Step: 11

      Install new handle. I drilled two holes in the walnut handle to accommodate the metal prongs sticking out from the teakettle. The handle fit on securely but a 2-part epoxy can be used if you don’t achieve a tight fight.

    12. Step: 12

      Screw on top knob. The top knob for a kettle screws off. I drilled a hole into the knob and then screwed it onto the lid.

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Wood Kettle Handle & Knob

by Homemade Modern
Feb 12, 2015

Carving with a drill is actually really easy. I used a brad point drill bit, a drum sander, and a carving bar to shape the handles. I really like the idea of partial DIY projects that result in an upgraded and customized object. I am excited to customize more of the stainless steel kitchen items with walnut handles so that they will match even though they are different brands. I use my Hario gooseneck kettle for making pour over coffee. I like everything about it except the plastic handles that it came with. I decided to carve new handles out of a scrap piece of walnut I had using my cordless drill. In addition to brad point drill bits I used a carving bur and a sanding drum. This technique can by used to make all sorts of wood replacement parts.

Project Steps

  1. Step: 1

    Trace the handle. I traced the outline of the original handle onto the wood with a pencil. I used a piece of 1-inch thick walnut that I had left over from a previous project.

  2. Step: 2

    Drill holes. I used a 3/16th diameter brad point bit to drill a series of holes around the traced outline. I like brad point bits for this task since their sharp points keep them from slipping when you drill holes right next to each other. I cut out most of the handle but left a small piece of it connected to the large piece of wood so that it would be easier to clamp and sand.

  3. Step: 3

    Carve. I clamped the wood to my worktable and used the carving burr to shape the handle.

  4. Step: 4

    Sand. Once I had the rough shape of the handle I switched to the sanding drum and smoothed down the handle.

  5. Step: 5

    Finish cutting off the handle. Now that the handle was shaped I cut it off from the rest of the wood with the drill. I used a knife to clean up a few drill marks.

  6. Step: 6

    Sand. I used 120 and then 320 grit sandpaper to finish the handle.

  7. Step: 7

    Stain. I finished the walnut with a coat of Danish oil.

  8. Step: 8

    Cut out the top knob. I didn’t like the design of the original knob. It was too close to the stainless steel and my knuckles would bump into the hot kettle when I would try and remove the lid. I drew a completely new profile for the wooden knob and then cut it out with the drill.

  9. Step: 9

    Carve and sand. I carved and finished the knob the same way as the handle.

  10. Step: 10

    Remove plastic handles. I drilled a series of small holes through the plastic handle and then used wire cutters to clip away the plastic between the holes.

  11. Step: 11

    Install new handle. I drilled two holes in the walnut handle to accommodate the metal prongs sticking out from the teakettle. The handle fit on securely but a 2-part epoxy can be used if you don’t achieve a tight fight.

  12. Step: 12

    Screw on top knob. The top knob for a kettle screws off. I drilled a hole into the knob and then screwed it onto the lid.