Probably the easiest/cheapest option is to use a Dremel tool with the drill press optional fixture.
Once you set it up for depth, you use the Dremel with a small wood router cutting bit, and work the wood under it like its a pin router.
In other words, you lower the Dremel to the depth you want to cut, then move the wood under the cutter to route out the recess.
Then you reset the depth for the cut that fits up on the frame and route that area.
There are several ways to utilize the wood.
One is to simply use planks. In this case, neither side will match the grain.
This is how Colt made their grips.
Method two is to use a block of wood cut in half. The grain will flow evenly from one half to the other interrupted.
Method three is to cut the block of wood in half, then turn the halves inside out. This gives the same grain on both sides of the grips. This is sometimes called "book matching.
The Dremel drill press and router cutter works very well, and is essentially how the factories do it, only this is guided by hand.
Last edited by dfariswheel; 01-16-2010 at 12:09 AM.
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