How to make grips?

rich5674

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Somebody gave me a nice piece of cocabolo. I'd like to make grips for my model 66 RB frame and get rid of the rubber. Is there a way to do a decent job using a drill press, band saw and router table?
 
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Somebody gave me a nice piece of cocabolo. I'd like to make grips for my model 66 RB frame and get rid of the rubber. Is there a way to do a decent job using a drill press, band saw and router table?
 
Yes. Attractive and functional grips are well within the capabilities of good woodworkers. I've done a number of them, and even without using a duplicating machine, they come out looking and feeling good.

I start by slab cutting the cocabolo, to get two pieces with matching, continuous grain. That is how S&W does their target grips.

Power sand the inboard (frame side) flat on both pieces. Trace or transfer the semicircular cuts at the top of the frame cutout to the slabs. Transfer the frame locating pin holes and drill. Drill the screw attachment holes and counterbore for the threaded fastener head and shank.

I glue the inletted slabs to a piece of plywood and clamp to the workbench. A piece of brown paper sack paper between the plywood and the slabs makes them easy to pry off later. Use hand router and inletting chisels to fit slabs to the frame. Once you have the inboard sides inletted to fit the frame, you can attack the outside curves.

Trace and transfer the outside profile to the slabs. Bandsaw to rough shape, using a power disk sander to bring it close to correct profile. Use router table with appropriate radius cutter (with roller guide) to bring the slabs to finish shape, and use rasp, files, and sandpaper to finish.

The final shaping and finish should be with grip slabs attached to the pistol, and make the finished contours match your hand exactly. Finger grooves can be added at this time. Checkering, a little bit tricker, can be done later.
 
If you are doing final shaping on the gun, please add a piece of tape - I use electrical - to protect the frame from nicking. When I get down to the tape I remove the grips and hand sand a tad closer. Good luck.
 
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