Make Perfect Star Knobs with a Knob Jig (DIY Step-by-Step)

About the author, Lukas — Mon, 25 Oct 2021 10:53:36 +0000

AllFlavor Workshop

Make Perfect Star Knobs with a Knob Jig (DIY Step-by-Step)

It’s incredibly useful to have a knob jig in your workshop — especially if you’re building jigs or machines for your shop. A star knob is perfect when you need to tighten, clamp, or adjust something. Thanks to their ergonomic shape, they offer a secure and comfortable grip.

You can make knobs without a jig, but it’s so much faster and more accurate with one. Plus, you can make several at once and stock up for future builds.

On top of that, you’ll save a lot by making your own wooden knobs. If you’re building your workshop on a budget, this is a must-have jig — simple, affordable, and useful.
You’ll find step-by-step instructions below, and I’ve also included a free PDF with the knob jig plans if you’d like to download and build it yourself.

🔗 Related Articles

DIY Star Knob Jig Video

If you want to see how it’s done in action, check out the full build video below. I walk you through every step of the process — from cutting the jig to drilling perfect wooden knobs.

🎥 Watch the video and build your own star knob jig today.
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Star Knob Jig Video
Star Knob Jig Plans PDF
Materials and Tools
Types of Knobs Explained
1. What is a Star Knob?
2. What is a Wood Knob?
3. What are Clamping Knobs?
4. Comparison Table
How to Make a Star Knob Jig
1. Step 1: Make the base
2. Step 2: Draw the design on the base
3. Step 3: Cut the inner circle
4. Step 4: Install a T-nut and a Threaded Rod
5. Step 5: Cut Holes for Different Star Knobs
6. Step 6: Finish the Star Knobs
How To Make Star Knobs with a Knob Jig
My Take
FAQ – Frequently Asked Questions
Jigs Used for the Project

*Safety is your responsibility. Make sure you know what you’re doing and take all necessary safety precautions while working with power tools. Safety comes first!

Star Knob Jig Plans

Download the Star Knob Jig Plans here

Download plans here

Material and Tools You'll Need

Here’s everything I used to build the knob jig and make the wooden star knobs. You probably have most of it already in your workshop.

Star Knob Jig – Materials

2× Birch Plywood – 170 × 100 × 12 mm (base of the jig)
Threaded rod ø6mm – https://amzn.to/48wzmps
Wingnut, T-Nut, and Washer for a ø6mm threaded rod

DIY Workshop Drill press

Check all the Tools I Use

Tools:

Other

Forstner Drill Bits – ø10mm, ø15mm – https://amzn.to/3Hd1aDb
Hole Saw Cutter Drill Bits – ø38mm (ø42mm) – https://amzn.to/48Qpk2o
Drill bits for wood – ø2mm – https://amzn.to/4aI47t3
4x Wood Screws – 3 x 20 mm
Dowel ø10mm
Wood Glue – https://amzn.to/48ltKhJ
Epoxy Resin – https://amzn.to/3tJ5R4L
Sandpaper Sheets – https://amzn.to/41OMx2p
Hardware Assortment Kit – https://amzn.to/41PodgQ

We may earn a small commission when you buy through these links. As an Amazon Associate, AllFlavor Workshop earns from qualifying purchases.

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Build your own wooden star knobs with this simple jig. A great way to upgrade your workshop without spending much.

Types of Knobs Explained

When you’re building jigs or workshop tools, understanding the different types of knobs helps you choose the right one for the job. Here’s a breakdown of the most common types you’ll come across—and how they’re used.

What is a Star Knob?

A star knob—also called a lobe knob or scallop knob—is perfect for clamping, tightening, or adjusting parts of jigs and fixtures. Thanks to its ergonomic star shape, it gives you a strong, comfortable grip and better control when applying pressure.

They typically come with a threaded stud or a tapped hole in the center, depending on how you want to attach them.

🔧 Best for: Adjustable clamps, T-track hold-downs, jig fine-tuning

What is a Wood Knob?

A wood knob is simply a rounded grip or handle made from wood. You’ll see them used as drawer pulls, door handles, or furniture accents. You can turn them on a lathe, shape them by hand, or cut them from a template (like in this project).

They’re decorative and practical—and when shaped right, they work great on jigs too.

🪚 Best for: Handles, furniture hardware, DIY jig grips

What are Clamping Knobs?

Clamping knobs is the general term for knobs used to tighten, fix, or secure things in place. Star knobs fall into this group, along with:

Ball knobs
Wing knobs
Knurled knobs

They’re often made of plastic or metal in store-bought jigs, but you can easily make your own from wood using a jig like this one.

⚙️ Best for: Versatile clamping and adjusting in jigs and machines

Comparison Table

Type of Knob	Shape	Main Use	Common Materials
Star Knob	5 or 6-point star	Clamping, tightening, jig tuning	Wood, plastic
Wood Knob	Round / decorative	Handles, furniture knobs	Wood
Clamping Knob	Star, wing, ball, knurled	Fixing, adjusting, securing parts	Wood, plastic, metal

Keep in mind, that the bits you choose greatly affect the accuracy and cleanliness of your cuts. I recommend the ones below. They do a great job and are not that expensive.

IRWIN Forstner Bit Set

Ultra-Sharp Cutting Teeth Specifically Engineered To Cut Through Hard And Soft Woods Smoothly And Efficiently

Image: Amazon

Let's Start

The knob jig is made from Baltic birch plywood and used together with a drill press stand. Once mounted on the drill press table, you can easily and repeatedly create consistent star knobs—no measuring or re-drawing needed each time.

The overall dimensions of the jig are 170 x 100 x 24 mm, and it’s designed to work with several different star knob shapes. The jig consists of two plywood layers joined with screws, along with a threaded rod and T-nut in the center to secure the workpiece.

I used Baltic birch, but you can use other types of plywood or hardwood scraps as well. If you’re not sure what to go with, check out this quick guide on the best materials for woodworking jigs to see what works best for strength, precision, and durability.

You’ll also need a few common woodworking tools (like a hole saw and Forstner bits) and some scrap plywood, which makes this a great project if you’re building a workshop on a budget.

How to Make a Star Knob Jig

Step 1: Make the base

Start by cutting two plywood pieces for the jig base — each 170 mm long and 100 mm wide, ideally from 12 mm Baltic birch plywood.

Next, mark the corners of one of the plywood pieces – 20 mm from each edge. Clamp both plywood pieces together and predrill the corners using a 2.5 mm drill bit. Then countersink the holes so the screw heads sit flush with the surface.

Screw the two plywood pieces together using 3×16 mm wood screws. This is just a temporary hold — you’ll take them apart again later.

Step 2: Draw the design on the base

Flip the jig over so the bottom piece is facing up. Mark the center point of the base — this will be the center of your star knob design.

Draw two concentric circles:

Inner circle: Ø38 mm
Outer circle: Ø42 mm

Next, divide the circle into six equal segments, drawing lines every 60 degrees. This will guide the placement of holes to form the star points later.

✅ Tip: Use a compass and a protractor or angle finder to get accurate spacing. Precision here helps with consistent star knob shapes.

Once you finish the layout, you’ll have a clear visual guide for both shallow and deep star knob versions.

Step 3: Cut the inner circle

Start by drilling a small center hole (ø2.5 mm) through both plywood pieces at the center point you marked in the previous step.
This small hole helps align both parts later, especially when working on them separately.

Now disassemble the two pieces and set the bottom one aside.

Take the top piece (the one with your drawn design) and use a ø38 mm hole saw with a ø6 mm center bit to drill a clean hole right at the center.
This hole will define the inner boundary of your star knob.

🔧 Why ø38 mm?
This size works great for knobs using a 6 mm bolt or 20 mm T-nut — a practical, comfortable diameter for most jigs.

Once the hole is cut, you’re ready to move on to installing the hardware.

Step 4: Install a T-nut and a Threaded Rod

Now let’s prepare the base of the jig to hold the threaded rod securely.

Take the second plywood piece (the one you set aside) and drill a ø20 mm hole in the center using a Forstner bit. This hole should be just deep enough so the head of the T-nut sits flush with the surface — no deeper.

Next, slightly enlarge the center hole with a ø7.5 mm drill bit, but don’t drill all the way through. This step ensures the T-nut fits snugly without protruding on the bottom.

💡 TIP: Need options?
Check out these different ways to install a T-nut depending on your project’s needs.

Now press the T-nut into place using a clamp. Make sure it sits flush and doesn’t stick out — the jig needs a flat surface to rest on.

Once the T-nut is in, reassemble both plywood pieces and screw them back together.

Cut a 30 mm piece of ø6 mm threaded rod, clean up the edges with sandpaper, and screw it into the T-nut.
If you want a more permanent hold, add a small drop of epoxy where the rod meets the nut.

💡 TIP: Alternate mounting methods
If you prefer, you can drill straight through both plywood layers and install the T-nut or a bolt from the bottom. Just make sure everything sits flush so the jig stays level.

Step 5: Cut Holes for Different Star Knobs

This knob jig design allows you to create two types of star knobs — both with six points, but with different cut depths (shallow or deep). Each method offers a slightly different look and grip feel.

You can use the jig as-is or modify it to suit other star knob configurations.

1. Star Knob with Shallow Cutouts (with Dowel Stop)

This version uses a 10 mm dowel pin to hold the knob in place as you drill.

First, cut out a circular knob blank using a ø38 mm hole saw.
Then, mark all six lines on the face of the knob — 60° apart — to match the star pattern.
Place the circle on the jig, align the lines with the base design, and fix it in place with a wingnut.
Use a ø10 mm Forstner bit to drill a hole at one of the line intersections along the inner circle (ø38 mm).
Insert the 10 mm dowel into this hole — it will serve as a guide pin to rotate the knob accurately.

With the dowel in place, rotate the knob to the next line, fix it again with the wingnut, and drill the next hole. Repeat the process until all six holes are drilled.

✅ Once this is done, you’ll get a perfect star shape every time—no need to redraw the lines on future knob blanks.

2. Star Knob with Deep Cutouts (No Dowel)

This version skips the dowel and uses deeper cuts for a more pronounced grip.

Use a ø15 mm Forstner bit to drill holes along the outer circle (ø42 mm).
To keep the pattern centered, draw at least one or two alignment lines on the knob blank.
Follow the same method as before: fix, drill, rotate 60°, and repeat.

This method gives you more aggressive points on the star knob, which can be helpful when you need extra grip.

📝 NOTE: Want different shapes?
To make knobs with fewer or more points, just change the layout lines on your jig — for example, use 120° for 3 points, 90° for 4 points, etc.

Step 6: Finish the Star Knobs

At this point, your knobs are fully shaped and functional — but a few finishing touches will make them more comfortable and professional-looking.

1. Mount and Sand the Knobs

Slide your completed star knobs onto a threaded rod.
Secure them with washers and nuts above and below to hold them firmly in place.
Mount the rod in your drill press and spin the knobs slowly.
Use low-grit sandpaper (e.g., 80–120 grit) to smooth out the edges and faces of the knobs.

⚠️ Important: Be careful not to hit the threaded rod with your sanding tool. Work slowly and keep your hands safe.

For more aggressive material removal, you can also use a rotary tool or bench grinder — but stick to sandpaper for final smoothing.

2. Optional: Add Epoxy or Finish

Apply wood glue or epoxy to fix the T-nut and bolt securely in place.
If desired, add a wood finish or oil to give the knobs a more polished look and protect them from wear.

Once you’re done, you’ll have durable, shop-made star knobs ready to use on any jig or clamp in your workshop.

How To Make DIY Wood Knobs

Here’s a quick recap of the process — follow these steps to make perfect star knobs every time using your jig:

Step	Description
1.	Cut a wooden circle using a hole saw (e.g. ø38mm)
2.	Place it on the knob jig, secure with a wing nut
3.	Drill the first hole at the marked 60° line
4.	Rotate the knob, insert a dowel for alignment, and drill the next hole
5.	Repeat until all 6 holes are drilled
6.	Insert a T-nut and threaded rod for mounting
7.	Sand the edges and cutouts for a smooth finish

This method makes it fast and repeatable — once your jig is ready, you’ll be able to produce star knobs for any jig or tool in your shop with ease.

Wrap-Up: My Take

I’ve used these DIY clamping knobs across a bunch of different projects in my workshop—and they’ve proven to be incredibly handy. Whether it’s for fine-tuning adjustments, holding down workpieces in T-tracks, or clamping multiple boards together, these star knobs really do the job well.

Here are just a few builds where I’ve used them:

They’re easy to make, cost next to nothing, and honestly—they look awesome once finished. If you’re building your workshop on a budget, making your own knobs like these is a smart, satisfying upgrade.

I hope this guide gave you everything you need to make your own knob jig and a batch of wooden star knobs. It’s a small jig, but it opens up a lot of possibilities.

👉 So, what do you think—ready to make a few star knobs of your own? Let’s build something great.

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FAQ: Making Star Knobs with a Jig

Can I make star knobs without a jig?

Yes, you can, but it’s slower and less precise. A jig ensures your cuts are consistent and symmetrical, especially when making multiple knobs for different jigs or fixtures.

What size T-nut or threaded insert should I use for DIY knobs?

A 6mm (M6) T-nut is commonly used for most jigs and clamps. It offers good grip and compatibility with typical shop bolts and threaded rods.

What’s the best wood for making star knobs?

Use dense hardwood or quality plywood (like Baltic birch). These materials hold threads well and resist splitting, especially around drilled holes.

Jigs Used for This Project

These are the jigs I have used to build the knob jig:

This post Make Perfect Star Knobs with a Knob Jig (DIY Step-by-Step) first appeared on AllFlavor Workshop and is written by About the author, Lukas

wood knobs – AllFlavor Workshop

Make Perfect Star Knobs with a Knob Jig (DIY Step-by-Step)

DIY Star Knob Jig Video

Table of Contents

Star Knob Jig Plans

Material and Tools You'll Need

Types of Knobs Explained

What is a Star Knob?

What is a Wood Knob?

What are Clamping Knobs?

Comparison Table

Let's Start

How to Make a Star Knob Jig

Step 1: Make the base

Step 2: Draw the design on the base

Step 3: Cut the inner circle

Step 4: Install a T-nut and a Threaded Rod

Step 5: Cut Holes for Different Star Knobs

1. Star Knob with Shallow Cutouts (with Dowel Stop)

2. Star Knob with Deep Cutouts (No Dowel)

Step 6: Finish the Star Knobs

1. Mount and Sand the Knobs

2. Optional: Add Epoxy or Finish

How To Make DIY Wood Knobs

Wrap-Up: My Take

FAQ: Making Star Knobs with a Jig

Can I make star knobs without a jig?

What size T-nut or threaded insert should I use for DIY knobs?

What’s the best wood for making star knobs?

Jigs Used for This Project