Aluminium extrusion parametric JIG

I had to create a drilling jig for myself, so I decided to make it parametric so that everyone can use it and customize it easily.

Available Files

• The Fusion 360 file, where you can modify the parameters:
  • Series: the type of extrusion (20, 30, or 40)
  • Groove Width: standard values are 6 for 20 series, 8 for 30 series, and 10 for 40 series
  • Nb Width: the width of your extrusion (e.g., a 3060 extrusion will be a series 30 with a width of 2 on the wide side)
  • Nb Length: the number of holes you want in the length of the extrusion
  • Bearing External Diameter: if you don't use a 625-zz bearing
  • Side Screw Diameter: for the locking screw (and matching hammerhead nuts)
  • 
• Standard versions in .stl format, such as 2 holes in a 2020 extrusion, 4 holes in a 2040 extrusion, etc.
• A tapping jig (in Fusion, I recommend using "Nb Length = 1 or 2" and "Nb Width = 1" for the best results)

Drilling Jig Description

The drilling jig uses 625-zz bearings to guide the drill bit, as these bearings have an internal diameter of 5mm and are commonly used in V-wheels, making them easily available from old 3D printer wheels. However, if you need a different drilling diameter, you can change the bearing by modifying the "Bearing External Diameter" parameter in Fusion 360. I used 2 bearings per hole.

Required Materials

• 4 M3 x 30mm countersunk screws for the drilling jig
• Hammerhead nuts with a hexhead screw to secure the jig during drilling. I strongly recommend using 20mm hexhead screws with a 3D-printed knurled head, such as this one: https://www.printables.com/model/328149-knurled-screw-knob-nut-m3-m4-m5-m6-m8.

Assembling the Jig

1. Insert the guiding hood into the main body where it belongs.
2. Use an extrusion to ensure everything is aligned.
3. Place the top hood on and screw the 4 screws, but not too tightly, or it might bite into the extrusion.

Tapping Jig

The tapping jig might not add much value, as there are already holes in the extrusion, so there's no real need for guidance. I made mine using this tapping tool: https://www.amazon.fr/dp/B07JWC5S6M?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1, and this drilling guide (screwed into the 3D-printed piece): https://www.amazon.fr/dp/B0DQXPJFJC?ref=ppx_yo2ov_dt_b_fed_asin_title.

Custom Jig Request

If you need a jig that's not available in the STL files, feel free to ask, and I'll try to upload it as soon as possible.

I hope this is helpful!