2020 Extrusion Cutting (sanding) Jig
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A jig for precisely cutting a flat edge on the 2020 extrusion
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I ran into a problem while cutting a 2020 extrusion profile by hand with a hacksaw. The cut was way out of plane.
This jig was made specifically to aid in finalizing edge shape with a dremel tool. It helps to ensure the edge stays perpendicular to the extrusion and the plane is (reasonably) flat.
Note that the plastic will not prevent your tool from digging into it, but it sure will help provide a reference plane anyway.
Holes on the sides are for M3 screws to hold the jig fixed to the extrusion while cutting (2 on neightboring sides is enough, but I made it 4 just in case threads in plastic get damaged).
Eye protection is absolutely necessary when working with cutting tools.
UPD 07.10.2024: Added a looser-tolerance version for V-slot extrusions