Spline Cutting Jig – Dual Version (Extrusion or Fully Printable)
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Adjustable spline jig for table/router saws using 20x80 extrusion or fully 3D printable rails.
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🧩 General Overview
This jig is designed to make cutting splines safe and repeatable on a table saw or router table. It holds your workpiece at a fixed 90° angle and glides smoothly across your tabletop. The design supports two build paths: using 20x80mm aluminum extrusion or a completely 3D-printed rail system.
🛠 Version 1: Aluminum Extrusion
Uses standard 20x80mm T-slot aluminum extrusion
Printable parts: 2x bracket assemblies (each includes the support wing and rail)
Orientation: print with the triangle side flat on the bed and vertical face upward
Material: PLA works, but PETG is preferred for its lower tabletop friction
Aluminum can be cut with a basic saw—rough edges are fine due to internal mounting
🧱 Version 2: Fully Printable
Replaces aluminum rails with 3D printed parts
Great for users without access to saws or who prefer a fully printable build
Print rails vertically to maintain straightness and strength
Tip: reduce print acceleration to prevent shifting on tall prints
Printable parts: 2x bracket assemblies, 2x vertical printed rails
Use the same print orientation for bracket assemblies as in Version 1
🖨 Material & Print Settings
Recommended filament: PETG for smoother surface glide; PLA is acceptable
Bracket assemblies: triangle flat on the bed, vertical face up
Rails (if printed): vertical orientation with reduced acceleration
Standard settings work well; optionally increase wall count and reduce infill
📦 Aluminum Extrusion Link:
uxcell 20x80 Extrusion on Amazon
⚠ Important: The bracket assemblies for Version 1 and Version 2 are not interchangeable. The track alignment is slightly different between real aluminum extrusion and the printed version—make sure to print the correct files for your chosen build.
🧷 Assembly Instructions
Hardware Needed:
16x M5 x 10mm screws
16x M5 T-nuts
20x80 aluminum extrusion (for extrusion version only)
Steps:
Insert T-nuts into the track
Align each bracket assembly to the nuts
Loosely insert all screws
Square up the jig
Fully tighten all fasteners
Note: I haven’t printed this jig yet as I’m currently focused on a larger project, but I’ll upload photos once I do. Stay tuned!