Easy Palm Size DIY Pocket Bottle Opener
Here is a really quick project you can do before the holidays. It’s a very easy palm size pocket bottle opener. These only require a few tools and you can knock them out from wood from your scrap bin. And they are easy to use. Because these DIY Pocket Bottle Openers are only 2” x ¾” they fit in your pocket, backpack, cooler, or picnic basket. You can give them as gifts or stash a few around the house and your shop for easy access. By the way – please do not drink and operate power tools – bad things can happen.
And follow this link to my Video to see how it is done. VIDEO LINK
Tools and Materials
First you will need a piece of wood about 2-1/2” to 3” wide, 3/4″ thick, and long enough to get it secured in a vice or jig. Then you need a way to make a hole. I used a 15” Floor Drill Press but you only need something like a WEN 8” or 10” Bench Top Drill Press. So, why do you need it? To get the holes and cutout concentric. Using a Drill Press is WAAAY easier than trying to do it by hand. You can of course give that a try. You will also need a 1-3/4” Forstner Bit as well as a 1” Forstner Bit. I recommend a good Forstner Bit Set because you will probably use these more often than you think. And you will need a 2-1/4” Hole Saw. It will make a 2” to 2-3/32” plug. Last, if you choose you can use a compact Router and an 1/8” roundover bit.
Layout
This project really has no layout if you are using a Drill Press other than marking a point about 1-1/4” in from the end and the side to give you a center point. But here is a dimensioned sketch.
Set Up and Drilling
First thing to do is to secure your piece on your drill press table. Be sure that it will not move – this is critical to getting concentric holes and the cutout. When your are setting the drill press table height make sure you have enough room to get the drill bits out when you need to swap them.
Start with the 1-3/4” Forstner Bit and drill down enough for the metal opener piece to be fully recessed or just sub-surface to allow for sanding. This will be about 1/16” deep.
Next swap out for your hole saw bit. Be sure you take the drill out of the center. You don’t need it and you certainly done need the hole it makes. Drill down just enough to score the surface and look closely to make sure you have a consistent ring. If you setup was solid then it will be perfect. Continue drilling with the hole saw down about 1/2”. Then swap it out for the 1” Forstner Bit.
BE CAREFUL the Saw Bit will be hot!!
With the 1” bit in drill down about 3/8” deeper being very careful not todrill through the part. Be sure the Forstner bit point doesn’t come through the other side of the part. My Forstner bits have very short tips.
Parting the Blank
Next, you need tpo part the blank form the base wood. Re-chuck the hole saw and finish cutting the part free. By the way you could use a bandsaw to do this too. It is easier than getting the plug about of the hole saw unless you have the Lenox Hole Saw Bit I linked at the bottom. Here is a really nice 9” Bench Top Bandsaw by Shop Fox that would be a great addition to any shop. BTW I have a 14” Delta.
Sanding
With the piece cut out you will need to file and sand the edges. This is a pretty straight forward effort – just make sure you keep it round and concentric. You can do this entire operation by hand or you can do what I did and use an Oscillating Belt Sander. The sander will make short work of the initial shaping with 80 grit and with a belt swap to 220 grit – BANG – you are done!
BE SURE YOU ARE USING DUST COLLECTION WHEN USING A POWER SANDER. You don’t want to find out you have COPD at age 65 because of breathing wood dust.
Routing
You can at this point continue sanding and round over the top edge. You will have to use this method if you want a radius greater than 1/8”. There is no good way to hold the part and router puts too much torque on the it if you try a 1/4” radius bit. All that said grab your compact router and a 1/8” round over bit and get that thing rounded. . I recommend setting the part on something like the Powertec Non-Slip Woodworking Mat to keep the part in place.
At this point give everything a once over with 320 grit as it will be in you pocket or hand regularly. And I used my custom electric branding iron to permanently mark them too.
Finishing
Finishing is up to you. I used a Minwax Pecan stain follow by two coats of Boiled Linseed Oil and 320 grit sanding in between. Final coat was Paste Wax
Assembly
Assembly is easy. The first step is to position the metal opener in the recess. Next mark the center of the holes with an awl. You will probably need to predrill for the screws – I used a cordless rotary tool and chucked a 3/32” bit in it to sink the holes.
Next, mixed some 5 Minute Two Part Epoxy and spread it in the recess. You won’t need much and you don’t want any squeeze out. If you do get some epoxy squeeze out you will need to wipe it off with Acetone before it dries. Once you have the metal opener in and positioned over the holes you drilled, use a small Phillips screwdriver and secure it in place with the screws. Wait for about an hour for the epoxy to fully cure.
Wahoo – you are done!! Grab a beer and try it out!
Well I hope you got something out of this DIY Pocket Bottle Opener and will give it a try in your shop. If you do, let me know and post a comment to my Facebook page. I’d love to see what you are working on.
Thanks for reading and until next time Good Making!
Bill
Visit my Etsy Store at www.etsy.com/shop/30MinuteWoodshop
Facebook https://www.facebook.com/30MinuteWoodshop
Link to my [WHATEVER] Video
Whiskey Display Video https://youtu.be/vVuqMnA4IPo
Barrel Stave Bottle Opener Blog https://30minutewoodshop.com/barrel-stave-bottle-opener/
Mid-Century Modern Two Tier Plant Stand Video https://youtu.be/kmgkzB6utZA
Tools you may need
10 Set Bottle Opener Insert Kit https://amzn.to/3WoXLae
LENOX Tools Hole Saw – 2-1/4-Inch https://amzn.to/3FABgs8
Freud 16PC Diablo Forstner Drill Bit Set https://amzn.to/3FC4sim
WEN 10-Inch Drill Press with Laser https://amzn.to/3HKZcf8
Shop Fox 9″ Benchtop Bandsaw https://amzn.to/3BHA5FS
Ridgid Oscillating/Edge Belt Sander https://amzn.to/3Wcvcgn
DEWALT Router Fixed/Plunge Base Kit https://amzn.to/34TeXzp
Router Bits Sets of 24A Pieces 1/4 Inch Shank https://amzn.to/3I5SYU7
Powertec Non-Slip Woodworking Mat Pad https://amzn.to/3Yy2IPW
Electric Wood Branding Iron https://amzn.to/3Wsqaw8
1 qt Minwax Golden Pecan Wood Stain https://amzn.to/3G1afzn
LinSheen Boiled Linseed Oil https://amzn.to/3HGOxSw
Dremel Cordless Rotary Tool https://amzn.to/3jexdu0
