Step 10: Buttons are for pressing
Construction of the push button caps
This is a really simple process which can produce a very unique look for your faceplate. The stock plastic button caps are fine but a little generic looking, plus.. they add another material to the box (wood - metal, now plastic?) and I feel 2 materials gives a less cluttered feel to the design.
Using the drill as a lathe to make button caps from a dowel rod
1) Cut a small length off the rod, place in the drill and round the end with sandpaper.
2) Mark and drill a pilot hole, then a hole big enough for the button shank
3) Paint the wooden button cap to seal it and then glue on to the button shank.
The Volume control knob
This is a little more detailed. Following the images below
(Image 1) Cut a circle on the scroll saw
(Image 2) Round the corners with the drill sander
(Image 3) Clamp a piece of very fine sand paper to the bench and with your other and pull on the paper enough so that it forms a curve around the piece your working on when you sand. This will allow you to smooth out any edges.
(Image 4) Drill out a dowel to fit the control that needs to rotate. In this case I have drilled a small center hole for the screw and a larger hole that fits around the volume control rod which the screw goes in to.
(Image 5) Use the correct Wood/Metal glue and attached the screw in to the smaller hole in the dowle
(Image 6) Cut the dowel and use woodglue, clamp lightly and set overnight.
Various grit sandpaper roll from Harborfreight