Steel thumbscrews & jig

What I’m making: M8 wingbolt

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Made these tabs to weld onto bolt heads (details in CAD file below)

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Replacing these plastic ones (some have broken)

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

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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)

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Countersunk 90° included angle (underside)

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Marked all & drilled (8mm) holes in uprights

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Going to plug weld (MIG) through holes to base

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Using a wingbolt tab, as a spacer, wrapped in masking tape to add some clearance

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Welded

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Dressed with angle grinder flapwheel

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Marked and sliced through only the angle iron sections

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Cleaned up

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Nuts, bevelled, threaded & marked. From hex stock

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90° included angle

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Different threaded nuts

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Nuts hold the bolts in good contact & alignment

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Tabs are centre marked, drop in with good alignment, ready for welding

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What’s in the CAD file

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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.

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125mm x 127mm x 15mm 5083 Aluminium Plate

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Glued on cad template (link below)

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Optical centre punch (link below)

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Centre drilled used as fluffer (minimizes deflection) prior to pilot drilling

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Pilot drill all holes 3mm

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6mm drill

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Cut out profile

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Filed. A good selection of files helps; the dreadnought type is especially good on aluminium.

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Cleaned up a little more

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…and a little more

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Homemade edge chamferer/deburrer from an old three square file

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Drilling ready for threading m12 inserts

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Threading

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Countersinking

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Inserts: centre drilling

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Countersinking a relief to stop the slot in the screw snaping the twist drill used in the next operation

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Drilling to finish size

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Stamping sizes on the heads (there are 5 different sized inserts in my set)…

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Inserts fit nice…

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Insert needs to be below the surface on both sides

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Main body finished & inserts finished.

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Marking out the fences for the tool

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Cutting the parts

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Drilled, tapped,assembled to slider blocks and lapped flat

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Wallop….

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Underside

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

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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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Sliding bevel

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knoba – Radius keepers

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Wood work bench

4″ thick top with custom stainless steel fastners

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