I made these bottle openers for the members of my Movember team. They were a thank you gift for growing their mustaches to rise awareness for men's health issues. They would make great gifts for anyone or just make one for yourself.
Step 1: Gather you materials - Get your tools
Materials - 1/8" x 2" x 6-1/4" Aluminum bar stock
2 - 1/8" x 7/8" x 3-1/2" wood of your choice. If you use a laser or CNC to cut the handles start with a larger piece
2 - 3/16" Chicago screws
Tools - This is what I used. It is definately NOT the only way to make them. Since I had access to a CNC mill and a laser cutter I used them. The project could be made without either. Saws and sanders would work just fine. Since I was making multiples and I wanted them all to be the same, I used the CNC.
Techno CNC Mill
Epilog Zing laser engraver/cutter
Drill Press and Bits
Dremel with sanding drum
Step 2: Drill holes
I decided to drill holes in the blank in order to hold it down. I did this so I would not have to worry about removing tabs later in the project. If you have a better hold down system (vacuum table) use that.
1. Mark the center-line
2. Layout hole locations
3. Center-punch marks
4. Drill holes - I drilled 9/64" holes so there would be no movement when the blank was screwed down and then redrilled them to the proper size for the Chicago screws at the end
Step 3: Mount Blank
I used 2 screws to hold the blank down. I found using a fence along one edge prevented the workpiece from racking during the cutting process
Step 4: Mill the part
I used MasterCAM to to create the G-Code
Set up your mill
Run your program
I used dish soap as a lubricant to prevent the aluminum from melting and ruining your bit and project
I've attached a .pdf for those that don't have a CNC machine. You can print it out, transfer it to your stock and cut it out with a jewelers saw
Step 5: Bevel the edge of the opener
Use a Dremel with a sanding drum (or a file) to bevel the edge of the opener. This is necessary to get under the lid and lift it.
Step 6: Make the handles
Use 1/8" wood
I used the laser cutter because I wanted to engrave the handles also. They could be cut in a CNC or made by hand.