1515 Beam Cutting Jig

           This jig is designed for the precise cutting of 1515 aluminum extrusion or square carbon-fiber tubes using a jigsaw. It securely locks onto the beam with an M3×8 screw and square nut, ensuring stability and accuracy during cutting

Overview

This jig provides:

• A jigsaw guide slot sized to fit most standard jigsaw bases

• A bottom‑mounted M3 screw clamp that tightens into a square nut on top

• A T‑slot engagement system for 1515 beams

• An optional support bracket for keeping long beams level during cutting

The design ensures the beam stays fixed and aligned while you cut, reducing vibration and improving accuracy.

How It Works

🔩 Clamping System

• Thread an M3×8 screw upward through the bottom hole.

• Insert a square M3 nut into the upper recess.

• The screw fit is intentionally snug to prevent wobble.

• Tightening the screw pulls the nut downward, locking the jig into the 1515 T‑slot.

For beams without T‑slots, simply remove the screw and use the jig as a surface guide.

🪚 Cutting Guide

• The top slot accepts most jigsaw blades.

• Mark your cut on the beam.

• Slide the jig into position.

• Tighten the screw to secure the beam.

• Clamp the beam to your workbench for additional stability.

• Cut along your marked line.

📏 Optional Support Bracket

For long beams, the included support bracket keeps the extrusion level with your work surface. Place it under the far end of the beam to prevent sagging.

Printing Recommendations

• Material: PLA, PETG, or ABS

• Walls: At least 4 perimeters

• Infill: 20% or higher

• Orientation: Print flat on the base for maximum strength

• Supports: None

Included Files

• Main cutting jig

• Optional support bracket

Usage Notes

• Always secure the beam to your workbench with clamps.

• Ensure the jigsaw blade is appropriate for aluminum or carbon fiber.

• Cut slowly to maintain accuracy and reduce chatter.

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