Drill Alignment / Angle Tool

thingiverse

Here's my rendition of a 3D printed drill angle/alignment press for 4x (3.5”) or 6x (5.5”) material at either a 45 or 90 degrees. Only three parts need to be bought: brass or bronze bushing (.500id x .750od x .500 long overall w/1.00x.125 deep flange...included in length), Harbor Freight drill chuck #45731, and a ½ x 20 x 1.5 bolt. If you use a coupon for the chuck, you can come in at under $10 for all the stuff. I added some pics for assembly reference. The purchased items assemble in the "chuck holder". The chuck holder is assembled to the "chuck mount pad" with the "holder" and "holder keeper". This is the upper portion. Depending on manufacturing tolerances of the chuck, bolt, and bushing, you may want to pick up some small thin washers to put in the end of the chuck where the ½ 20 bolt threads in, this may help with the preload on the chuck holder. There's a little more going on with the lower portion. The base plate is setup for 90 and 45 holes and has clamp tabs. The tabs are .080 thick so with a 1mm top and bottom layer these should be solid with no infill. I went fillet happy with the model, it adds strength and seems to make the tool path easier as it limits abrupt changes in direction. There are many varieties of guide rods: 90s, 45s, 4x material, 6x material, over-sized. “os” at the end of the file name means that it will allow for material that is .125 over the standard dimension...so they bump the width to 3.625; there are no over-sized rods for the 6x material as they use the “os” base “extension”. For the “os” files I included shims of .03125 and .0625 thickness to make up any difference. The “4x” or “6x” in the file name means those were made for the respective width. The 4x are longer and go past the base plate to align it to the material, the 6x just sit on top of the material as the base extensions are used for the alignment. The “c3.1” etc refers to the length and pairing so c3.1 and c1.3 are one side, with the first larger number being the longer one. I also made a rod clamp to use for clamping the rods to the material. The springs have a large and a small end. The large end goes in the base plate. I also made some spring risers if needed. There are also angled spring risers when using the 45* setup. With the exception of the spring risers and the over-sided rods this should be a no-support part. I made the tolerances on the tight side so some edges may need to be knocked down, etc. All being said this is a pretty accurate setup, as you can see I went through lots of test parts to make sure everything fit the way I wanted to perform properly. I've included some small test parts to verify the tolerances before a commitment to print this...it's long. The parts are a rod section, the top holder and bottom base. The rod (fillet side up) should be a tight fit in the base and the holder should be a hard slip fit, it will slide a lot better when it “wears” a bit, some light grease helps as well. Also, if any body has a good reliable model for a hex-shank drill chuck let me know, I'd like to redesign the chuck holder for one of those... Although this is a legit model in its current form I'm still going to tweak it like adding rack and pinion slides for the extensions and pivoting arms for multiple angles with one setup, maybe other stuff as it comes to me... If anything else comes to mind I'll add it here... Any comments, suggestions, ideas...totally open to them. If any solid model files are wanted let me know and I'll post them up... Print Settings: Printer Brand: Robo 3D Printer: R1 ABS + PLA Model Rafts: No Supports: No Resolution: 200 Infill: .15 Notes: .15 minimum infill Matter Control users, if model looks small scale 10