www.nutsvolts.com/index.php?/magazine/article/september2011_Collier
10"
7"
7
6
5
2
4
1
■ FIGURE 2. Assembly
detail; see Table 1 for
component identification.
(Bottom side shown facing
up for clarity.)
3
and the assembly drawings in Figure 2. Locally available
common parts — such as fasteners and aluminum bar
stock — are not included in the list. The only special tools
required for construction are thread-cutting taps of several
different sizes, and the corresponding tap drills. The part
numbers shown in Table 2 are for spiral point taps, a.k.a.,
“gun taps,” which can be used in a reversing power drill
or drill press. First, cut the extrusions to length as
indicated. A hacksaw cut would be sufficient, but most
power miter saws can cut aluminum and provide a much
cleaner result. In order to assemble the frame using the
extrusion connectors, the ends of the 10” pieces need to
be threaded 1/4”- 20. The hole through the center of the
extrusion is already the proper diameter to be tapped this
size. Figure 3 shows the usage of the extrusion connector;
1/4” diameter holes should be drilled 1/2” from the ends
of the non-tapped extrusions to provide access for a 5/32”
hex wrench to tighten
the connector. Note
that the T-nuts must be
inserted before the
frame is assembled:
four on the top side for
the knobs; four on the
bottom side for the
feet; and two on the
front side for the
rotating side supports.
Plastic end caps are
available which cover
the exposed ends of
the extrusion, mainly
for cosmetic purposes.
The leveling feet
and toggle clamps can
ITEM
1
T-nut, 1/4"- 20 thread
2
3
4
5
6
7
be attached to the bottom side once the frame is
assembled. Install a washer and nut onto each foot stud
before threading it into the T-nut; this will allow the feet to
be adjusted individually so that the jig sits flat on your
work surface. The mounting holes in the toggle clamps
don’t line up with the T-slot, so they will need to be
screwed down. Position each clamp and mark the hole
locations, then drill and tap partially through the extrusion
for #8-32 thread.
Thread Size Tap P/N Drill P/N
#6-32 2523A446 2930A49
#8-32 2523A447 2930A42
1/4"- 20 2523A411 2930A17
Table 2. McMaster part numbers for required
taps and tap drills.
Extrusion connector
Extrusion end cap
(optional)
Knob w/ threaded stud
Leveling mount
Toggle clamp
TABLE 1. MASTER PARTS LIST
QTY MFR P/N DIST P/N
2 80/20 #1010 McMaster 47065T209
(Two ft length; cut to size)
10 80/20 #3382 McMaster 47065T142
(Four per pkg)
4 80/20 #3381 McMaster 47065T155
DESCRIPTION
Aluminum T-slot extrusion
4
4
4
4
80/20 #2015 McMaster 47065T91
N/A McMaster 6479K88
N/A McMaster 23015T82
( 12 per pkg)
Fargoware FC- 20 MSC Industrial 76988120
De-Sta-Co 205-S www.mscdirect.com
Carr-Lane CL-150-HTC (Also available on eBay)
Board support rail
(see Figure 4)
Side support
(see Figure 5)
Foam compression plate
(see Figure 6)
2
2
1
September 2011 29