1/2 inch Kreg HD Pocket Hole Jig Alternative

thingiverse

I was on the hunt for a heavy-duty pocket hole jig suitable for handling materials thicker than 1.5 inches, but Kreg's Kreg HD came with a hefty price tag of $70. I decided to take matters into my own hands and create one myself. The design features a single bore setup that can easily be adapted for a double-bore configuration. To ensure accurate alignment with marks on the lumber, I incorporated a center notch at the end of the jig. Given that the shell of the jig provides most of its strength, I added several pockets to enhance clamping power and minimize plastic usage. For a drill guide, you can opt for the bronze option available from various stores or source one locally. When it comes to the drill bit, you have two options: either purchase a regular 1/2-inch bit and carefully grind down its tip or buy a brad point bit specifically designed for this purpose. You can find suitable bearings at Menards under part number 2020046, while MSC Direct offers an alternative option with product number 06453781. For screws, I used Spax #10 2 1/2-inch construction screws featuring wafer heads and available in both indoor and outdoor varieties.