Indexed Adjustable Pocket Screw Jig

thingiverse

I drew inspiration from roklobster04's outstanding design since I wanted to create a bolt-down jig instead of just a clamp-on setup. I made several adjustments: 1. Indexed the sleeve for 3/4", 1", 1.25" and 1.5" width of stock on the back, labeled 3,4,5,6 (as in quarters of an inch). Calibration was done against a Kreg jig in my workshop to ensure accuracy. 2. I modified the vise plate to accommodate a washer and either a bolt head or thread-locked nut behind the aluminum clamp plate. This allows for smooth movement as the screw is turned. 3. The knob was changed to take a nut and washer that secures it to the shaft, ensuring a firm connection. 4. Instead of using two slot-inserted nuts in the base, I opted for one single nut due to issues with backlash when cinching the shaft. The fit was extremely tight when printed in ABS, so I modified the gaps by adding about 0.5mm for clearance on sleeve and vise mating surfaces. Roklobster04's original design laid the groundwork for the basic setup, allowing me to make a few tweaks. The original design featured an aluminum plate countersunk to take a screw and fastener from the back side of the plate. However, I found it easier to thread the aluminum plate and use a screw from the back side, then file the screw extension on the vise plate flat. I have ordered McMaster-Carr flanged sleeve bearing number 9440T54, which I plan to try out. An update will follow once they arrive. Update: The McMaster-Carr bearings arrived and fit perfectly in the jig. Some CA was used to attach them securely, preventing slipping. Several test holes were drilled with great results. Tip: To set the depth collar on the drill bit, place a 1/8" spacer at the bottom of the jig first. Then drop the drill bit in and tighten the collar while the bit rests on the spacer.