Aluminum Extrusion Drilling Jig

thingiverse

To connect two aluminum extrusions at 90 degrees, simply tap the center hole in one of them and drill a precise tool hole in the side of the other. Drilling an accurate hole into a small groove can be challenging without a jig, which is why I created this simple drilling aid. This handy device uses standard metric nuts as drill guides because it's much easier to destroy plastic jigs with a drill. The nuts will likely become damaged during use, but they're more robust than plastic and serve their purpose well. It's obvious that the nut size required matches the hole diameter you're drilling for. For 2020 aluminum extrusions (20mm), you'll need an M5 nut with a 4.2mm drill bit. If you're working with 1515 aluminum extrusions (15mm), use an M4 nut and a 3.3mm drill bit. Place the nut in the slot, slide the jig onto the end of the aluminum extrusion, and drill away - it's incredibly easy to do so. For those who are metrically challenged, I recommend purchasing some metric fasteners; after all, you can't fix a deficiency with frogs' snakes! The design prints without supports if you orient it so that the round hole faces downwards. This drilling aid is licensed under BY CC-SA, allowing you to use it in your projects and even commercial products as long as you attribute the original design and provide sources. If you modify the design, ensure that your license is compatible with BY CC-SA; simply search for compatible licenses online if needed. To give proper credit, include a link to this page and/or the OnShape public project by Toxuin (that's me) in your project documentation, even if you make modifications.