I started on the door handles first. I got a 1/2" thick stainless plate and plasma cut the shape out, I then started smoothing them out with the 9 inch angle grinder with both of the clamp together to keep them the same.
| I then moved to a belt sander that I mount upside down in the same vise and lock the power on. This gives me a poor mans sanding table. I kept the handles together for this as well and once done I took them apart as shown here. Now they have a nice, even swoop.
| For the mount side I got a length of round and started the pocket. A mill would make this easier but I drilled the corners and center. I then used a die grinder to make the sides to match the flats of the door latch attachment point.
| I then ground the square out and cross drilled for the retaining pin. I also drilled for the handle attachment points.
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I then sanded it out and polished everything. Cut it off and drilled and blind hole tapped the handles.
| The 2 new ones with the original below.
| Used countersunk allen head screws to hold them on.
| Drew up a pattern that was similar in design for the window cranks. I did the same process as before and here they are after rough sanding. I did some hand filing to give it more detail around the knob mounts.
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Bought some new knobs that fit with the design and made up some contour pieces. Drilled and tapped the holes. Sanded out and polished everything.
| The completed cranks and I like how these turned out.
| Here you can see how they kinda fit together by design. Piece by piece I'm getting there.
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