|Mar 11, 2011, 12:01 AM|
Build a Fuselage Jig
Lacking any sort of jig or a magnetic building board, I decide I needed to make one. I don't have a fancy wood shop and am some what limited on tools.
After seeing some jigs online, I decided a "Slot jig" would be the easiest to fabricate with the tools I have.
After a quick trip to the hardware store, I obtained the following Items:
1) 12 x 48 Malamine board
2) Fourteen 4" Right angle brackets, All checked in store for squareness
3) Fourteen 1/4 - 20 x 1" Carriage bolts.
4) A box of 1/4 - 20 wing nuts - Cheaper by the dozen
B) 1/4" Down-spiral straight cutter / slot cutter bit
C) 3/4" Straight cutter bit
D) 16" Clamp guide fence
E) Triangle Square
F) Sliding Square
H) Razor Knife
J) Scrap support blocks
K) 36" T Square - not required but helpful.
First mark a center-line in the exact center of the board. The sliding-square is helpful for this. First with pencil and then using a T-square and a Razor knife, razor the line in - not to deep, This make a permanent accurate center line.
Then mark perpendicular lines for each slot 3" on center.
The mark the beginning and ending point of each slot.
Near the edge - not so close the board will break, near the middle close enough so that the brackets can close all the way together. use the sliding square to mark each start of each slot, then adjust it to mark the end of each slot.
Put the board on blocks and clamp it down so its not likely to move or shift
Using the 16" clamp guide fence Route each slot in two passes; 1/2 the depth on each pass.
Flip the board over and clamp it down again.
Route each recess for the bot heads. I used the slot cutter in the slot to locate where to put the clamp fence and switched to the 3/4" cutter, and re-calibrated the router depth for each recess EACH TIME However the ensured perfect alignment with the slot and the recess. Depth I used for the recess 5/32"
Clean all the label goo off the angle brackets
Then assemble your jig! and enjoy building straight fuselages!
You may need to use some wood shims and clamps to get everything perfectly straight / plumb
Check out my build log for aircraft I using this jig on.
You can build fuselages up to: 47" inches long and 8" wide max on this jig.
You could also attach larger hard wood uprights to the angle brackets.
I would love to have an Adjust o Jig; however they seem to rarely come up on eBay anymore. Some day I'll build a magnet board.
Please use all normal safety precautions when using power tools
|Mar 12, 2011, 12:31 PM|
Joined Aug 2004
Great job, I did the identical thing about 20 years ago except instead of brackets, I made wooden verticals but fastened in the same manner you did with carriage bolts through the slots. Still using it. Yours looks better than mine does.
|Mar 12, 2011, 01:22 PM|
Aurora Municipal, Illinois, United States
Joined Jul 2002
I made a similar one a few years back. Originally used the corner brackets but I bought cheap and discovered some of them were 3 degrees out of square. Wound going with wood instead. I sandwiched 1/4" oak strips between 1/4" sheets of poplar. I then sawed off 4" chunks and trued the sides on a disc sander. The black strips are pieces of rubber weather strips and make up for any the occasional odd shaped piece as well as padding. The main fixture is a 4' shelf from Menards.
|Mar 12, 2011, 03:46 PM|
Thanks all! Yep it's jigs like you guys have built that inspired me.
Some day soon I will get in a wood shop to make some wooden
|Dec 19, 2011, 08:00 PM|
So, to bring up an older thread:
I'm thinking about building something like this... How do you "pin" the wood down while you're building? Or does this come into play AFTER you've built your fuse sides? Do I use my balsa building board to construct the sides and then move to this to assemble the two sides together?
|Dec 21, 2011, 10:12 AM|
United States, VA, Forest
Joined Nov 2009
|Dec 21, 2011, 10:37 PM|
I have been watching Brotherhood of the rings as G-Man has some interesting jigs. He has not posted his fuselage jig build yet but here is his wing jig:
and it is quite a variation but he did an excellent job.
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