Thumb wheel jig

Jig & threaded blank
knoba - thumb wheel jig

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Freshly machined thumb wheel blank
knoba - thumb wheel jig

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knoba - thumb wheel jig

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Screw blank on underside of jig, locknut it, drill through one hole, use lock pin (silver coloured part), drill through other holes, deburr, fettle & smooth thumb wheel.
knoba - thumb wheel jig

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Nice!
knoba - thumb wheel jig

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knoba - thumb wheel jig

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What’s in the CAD file…
knoba - thumb wheel jig

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Materials:
1 x 60x60x16 mild steel plate
1 x M12x80mm bzp bolt
1 x M6x40mm 12.9ht Socket cap bolt
1 x m6 washer
1 x m6 nut

1 x 13mmx32mm o/d, m6 threaded, 6 series Aluminium blank

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knoba – thumb wheel jig – 2018.dxf

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Steel thumbscrews & jig

What I’m making: M8 wingbolt
knoba - Steel thumbscrews & jig

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Made these tabs to weld onto bolt heads (details in CAD file below)
knoba - Steel thumbscrews & jig

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Replacing these plastic ones (some have broken)
knoba - Steel thumbscrews & jig

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Stock used in making a welding & alignment jig (to help make the wingbolts)
knoba - Steel thumbscrews & jig

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Materials:
1 x 50x50x6 mm (2"x2"x1/4") flat section mild steel
2 x 50x25x3 mm (2"x1"x1/8") equal angle mild steel
1 x 100x14 mm (4"x9/16") hex bar mild steel

All pickled, de-smutted & deburred.
Jig copes with 6mm to 8mm (1/4" to 5/16") bolts

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8mm hole in centre (top side)
knoba - Steel thumbscrews & jig

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Countersunk 90° included angle (underside)
knoba - Steel thumbscrews & jig

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Marked all & drilled (8mm) holes in uprights
knoba - Steel thumbscrews & jig

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Going to plug weld (MIG) through holes to base
knoba - Steel thumbscrews & jig

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Using a wingbolt tab, as a spacer, wrapped in masking tape to add some clearance
knoba - Steel thumbscrews & jig

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Welded
knoba - Steel thumbscrews & jig

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Dressed with angle grinder flapwheel
knoba - Steel thumbscrews & jig

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Marked and sliced through only the angle iron sections
knoba - Steel thumbscrews & jig

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Cleaned up
knoba - Steel thumbscrews & jig

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Nuts, bevelled, threaded & marked. From hex stock
knoba - Steel thumbscrews & jig

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90° included angle
knoba - Steel thumbscrews & jig

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Different threaded nuts
knoba - Steel thumbscrews & jig

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Nuts hold the bolts in good contact & alignment
knoba - Steel thumbscrews & jig

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Tabs are centre marked, drop in with good alignment, ready for welding
knoba - Steel thumbscrews & jig

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What’s in the CAD file
knoba - Steel thumbscrews & jig

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knoba – steel thumbscrews & jig – 2018.dxf

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Adjustable dowel & drilling jig

Used for drilling blind holes, in matched faces, for dowelling metal or wood assemblies.
knoba - Adjustable Dowel Jig

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125mm x 127mm x 15mm 5083 Aluminium Plate
knoba - Adjustable Dowel Jig

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knoba - Adjustable Dowel Jig

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Glued on cad template (link below)
knoba - Adjustable Dowel Jig

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Optical centre punch (link below)
knoba - Adjustable Dowel Jig

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Centre drilled used as fluffer (minimizes deflection) prior to pilot drilling
knoba - Adjustable Dowel Jig

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Pilot drill all holes 3mm
knoba - Adjustable Dowel Jig

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6mm drill
knoba - Adjustable Dowel Jig

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Cut out profile
knoba - Adjustable Dowel Jig

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Filed. A good selection of files helps; the dreadnought type is especially good on aluminium.
knoba - Adjustable Dowel Jig

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Cleaned up a little more
knoba - Adjustable Dowel Jig

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…and a little more
knoba - Adjustable Dowel Jig

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Homemade edge chamferer/deburrer from an old three square file
knoba - Adjustable Dowel Jig

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Drilling ready for threading m12 inserts
knoba - Adjustable Dowel Jig

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Threading
knoba - Adjustable Dowel Jig

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Countersinking
knoba - Adjustable Dowel Jig

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Inserts: centre drilling
knoba - Adjustable Dowel Jig

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Countersinking a relief to stop the slot in the screw snaping the twist drill used in the next operation
knoba - Adjustable Dowel Jig

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Drilling to finish size
knoba - Adjustable Dowel Jig

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Stamping sizes on the heads (there are 5 different sized inserts in my set)…
knoba - Adjustable Dowel Jig

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Inserts fit nice…
knoba - Adjustable Dowel Jig

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Insert needs to be below the surface on both sides
knoba - Adjustable Dowel Jig

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Main body finished & inserts finished.
knoba - Adjustable Dowel Jig

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Marking out the fences for the tool
knoba - Adjustable Dowel Jig

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Cutting the parts
knoba - Adjustable Dowel Jig

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Drilled, tapped,assembled to slider blocks and lapped flat
knoba - Adjustable Dowel Jig

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Wallop….
knoba - Adjustable Dowel Jig

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Underside
knoba - Adjustable Dowel Jig

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knoba – Adjustable Dowel Jig – 2015.dxf (link below)
knoba - Adjustable Dowel Jig

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knoba – Adjustable Dowel Jig – 2015.dxf

knoba – Optical centre punch

knoba – Dewalt chop saw mods

Wiki – 5083 aluminium alloy

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Sausage handle Router jig

Designed in CAD & transposed, with the datum lines, to 3/4″ plywood template.
knoba - sausage handle router jig

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Makes repeatable side hand-holds…
knoba - sausage handle router jig

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LibreCAD – Open Source 2D-CAD

Dewalt – DW331K Heavy Duty Top Handle Jigsaw

Freud – 1/2″ (dia.) bearing flush trim bit

Freud – 3/8″ Radius rounding over bit

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Planer / thicknesser blade honing jig

Planer thicknesser blade honing jig

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Planer thicknesser blade honing jig

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Planer thicknesser blade honing jig

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Oak.

Planer thicknesser blade honing jig

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Mini V Blocks

Mini V Blocks
Mini V Blocks

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knoba – VBlock-AnglePipe we… 2008.dxf

knoba – Large V blocks

Hammerite – Direct to Rust Metal Paint

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V Blocks

V Blocks

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V Blocks

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V Blocks

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V Blocks

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V Blocks

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V Blocks

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V Blocks

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V Blocks

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V Blocks

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V Blocks

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V Blocks

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V Blocks

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knoba – VBlock-AnglePipe we… 2008.dxf

knoba – Mini V Blocks

Forum – mig-welding.co.uk

Hammerite – Direct to Rust Metal Paint

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