2040 Aluminum Extrusion DRILL Helpers

thingiverse

I built these to assist with drilling holes in 2040 extrusions. These are universal except for one piece designed specifically for the Prusa I3 bear mod. To get started, simply bolt these to the corner of your 2040 extrusion using two or more t nuts to secure the plate and a 13/64 drill bit to drill through each hole. They were crafted to be slightly smaller so that the drill bit cannot self-center. The long (bear mod) drill plate has two holes at 96mm from the edge. All other holes are randomly placed to help stabilize the plate as you drill. To enlarge the hole, you will need a step drill (Christmas tree bit) or larger drill bit. One set is called STD and the other is called Misumi. For Misumi extrusions, I found that the holes are slightly closer than in the STD version. After drilling, you will need to use a 4.2mm drill and an M5x0.8 tap to tap the holes that they must go into. Most extrusions already have predrilled holes for 4.2mm, so you only need to use an M5x0.8 tap. M5 x 0.8 x 25mm screws are long enough for 2020s if you want to drill through at 40mm, you will need a 45mm M5x screw. Only the left-hand sides were uploaded; to use on right-hand sides, simply use your "Mirror" function in your slicer.