|Project by Bags||posted 10-09-2013 11:02 PM||3449 views||20 times favorited||21 comments|
I needed to make 400 wooden “nuts” to fit on wooden threaded “bolts”. The nuts needed to be a hexagon shape, have a 3/4 inch threaded hole in the middle and be 5 cm from one parallel side to the other. In order to cut them as efficiently and safely as possible, I came up with this sled. Hopefully my description below (along with the pictures) makes sense.
What I did to build the sled:
1) Calculated all the angles and lengths that were needed ( I had to dust off my old high school trigonometry book
to do it but…)
2) Laid out the needed measurements on the jig bottom board
3) Installed individual fences on the jig bottom board – each fence separated the wooden blanks from each other and held the blanks at the proper angle (60 degrees) to the blade when the board was pushed through the saw
4) Installed short dowels to hold each wooden blank the correct distance from the blade and kept the blanks from moving along the jigs internal fences when the jig was pushed through – each wooden blank had 5/8 inch hole drilled in them
5) Installed a jig top board to keep the blanks from moving up and down
How it works:
1) Load the sled with blanks
2) Push both sides of the sled through the saw (the sled’s width gave me a good deal of safety)
3) Take the top board off and rotate all of the blanks around the dowel. Replace the top board
4) Continue to cut and rotate until all sides are cut.
The sled held 14 blanks at a time. The total time cutting 400 blanks was still measured in hours but I think it worked out pretty well. It was safe and I was able to “tile the plane” with the finished product.