Round bar making jig

Jun. 20/2021
I needed a 9.5mm plug for the pocket hole jig, so I decided to make a round bar making jig. I designed 8 types of round bars of 5 to 12 mm so that they can be made from square timber.Drawing
1.Used poplar timber for the part that serves as a guide for the trimmer. Cut to a thickness of 27 mm.
2.Cut to a width of 46.5 mm.
3.Use bubinga, which is hard and has high wear resistance, for the main body. Cut to a width of 66 mm.
4.Polish the surface with a drum sander.
5.Make a notch with a 19 mm bit.
6.Mark the drilling position. The Woodpeckers ruler is useful.
7.Counterbore of 10 mm * 30 mm depth.
8.Drilling 5 mm through hole.
9.Counterbore of 10 mm * 30 mm depth. And Drilling 6 mm through hole.
10.Counterbore of 12 mm * 30mm depth by forstner bit.
11.Drilling 7mm through hole.
12.Counterbore of 12 mm * 30 mm depth. And Drilling 8 mm through hole.
13.Counterbore of 15 mm * 30 mm depth. And Drilling 9.5 mm through hole.
14.Counterbore of 15 mm * 30 mm depth. And Drilling 10 mm through hole.
15.Counterbore of 18 mm * 30 mm depth. And Drilling 11 mm through hole.
16.Counterbore of 12 mm * 30 mm depth.
17.Drilling 12 mm through hole.
18.The main body that has been drilled.
19.Drilling holes in poplar wood guide parts.
20.The hole is one size larger than the hole in the main body.
21.Cut the groove with a 25 mm dish bit.
22.Since the hole position of 5 to 12 mm is slightly offset to the upper limit, there is a place where the grooves are deeply scraped off. It is necessary to fix it.
23.Drilling 3.8mm for guided member fixation.
24.Counterbore for countersunk screw.
25.Fix the guide member with Coarse Thread.
26.This is to correct the groove portions are too shaving, 1mm thick wood.
27.Paste it into a part that corrects it.
28.Modify the depths individually with trimmer.I actually use it and think it is necessary to fix it. I thought that it was better to make a shallow groove from the beginning.
29.Cut the end face.
30.This is a jig's leg Two-by-Four, and 3.3 mm perforated for fixation.
31.Securing the leg to the body
32.Marking the position to fix the trimmer with Magic Pen.
33.A 2.5 mm thick MDF so that the chips do not splatter, Makeing a plate that closes one side of the trimmer. After cutting out, Sanding the corner to round with a disk sander.
34.Drilling 6mm.
35.Make it a long hole so that the position can be adjusted.
36.Use the knob bolt of trimmer guide for fixation.
37.Since there is a gap, air for dust collection can be sucked in.
38.This is also a parts that improves dust collection efficiency. It is a cover that closes the window that is open at the base of the trimmer by processing a PET bottle. Height 45 mm * length 200 mm.
39.Attach velcro to both sides.
40.Wrap it around the trimmer base in this way and fix it with Velcro.
41.Hard to see in the photo, but the trimmer base window is blocked
42.Make a dust collection port with a 20A PVC elbow.
43.I forgot to take a picture of the process of making. Burn it with a burner, crush one side of the elbow a little, and then use a belt sander to cut it to a thickness of 27 mm so that it fits in the groove. The tip is stepped so that it can be inserted between the trimmer base and the jig.
44.The elbow is inserted between the base and the jig.
45.Engraving the name of the jig with a laser.
46.It can be stamped like this with an output of 3.5W, 100%, and 2500mm/min.
47.Similarly, engrave the diameter of the round bar and the dimensions of the blank square lumber.
48.The C dimension represents the chamfer dimension. This is a painstaking measure. If the square timber was designed with larger dimensions, such chamfering would not have been necessary. It is the second of remorse.
49.The front of the completed jig.
50.Seen from above, the board pasted by adjusting the depth is sad.
51.From here, we will make a socket to turn the square timber. First of all, cut out 20 * 16 * 60 L square lumber with japanese ash.Drawing
52.Polish the surface with a disc sander so that it fits into the aluminum channel.
53.Cut the aluminum channel to a length of 35 mm.There is a hole because I used a junk item.
54.Glue japanese ash and aluminum with Cemedine Super X.
55.Grasp the aluminum side with a four-claw chuck and turning the other side to 9 mm.
56.Next, grab the round bar with a three-claw chuck and make a pilot hole for a square hole.
57.Corrected to a square hole with a chisel.
58.Completed 4 types of sockets.
59.To use the socket, first chuck the socket with a drill.
60.Then insert the square timber. The square holes should be slightly tight.
Then how to use.First, fix it to the work table with an F-type clamp.
The trimmer can also be firmly fixed with an F-type clamp.
Dust collection is perfect.

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