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Old Mar 11, 2011, 12:01 AM
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CADGURU's Avatar
United States, TX, Arlington
Joined Feb 2011
53 Posts
Mini-HowTo
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

Tools Required:
A) Router
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
G) Pencil
H) Razor Knife
I) Clamps
J) Scrap support blocks
K) 36" T Square - not required but helpful.


Steps:
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.
http://www.rcgroups.com/forums/showt...6#post17612911

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
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Last edited by CADGURU; Mar 13, 2011 at 12:14 AM.
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Old Mar 11, 2011, 09:46 PM
My plans are in my blog
Rusty-Gunn's Avatar
Kotzebue, Alaska
Joined May 2006
5,416 Posts
Sweet, baby, sweeeeet! I might have to do something like this.
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Old Mar 12, 2011, 11:58 AM
Are we having fun yet?
paullie's Avatar
USA, NY, Clarence
Joined Jan 2010
386 Posts
This is great! Thanks for sharing. Just in time for my next build.
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Old Mar 12, 2011, 12:31 PM
Registered User
Florida
Joined Aug 2004
4,138 Posts
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.
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Old Mar 12, 2011, 01:22 PM
Registered User
Aurora Municipal, Illinois, United States
Joined Jul 2002
1,588 Posts
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.
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Old Mar 12, 2011, 03:46 PM
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CADGURU's Avatar
United States, TX, Arlington
Joined Feb 2011
53 Posts
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
Fixtures.
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Old Mar 12, 2011, 06:01 PM
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USA, PA, Westmoreland Co.
Joined Aug 2008
1,339 Posts
very nice work and design
thanks for sharing the idea
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Old Dec 19, 2011, 08:00 PM
Plane crasher
jbswear's Avatar
United States, MD, Bowie
Joined Nov 2011
77 Posts
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?
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Old Dec 20, 2011, 07:48 AM
ARFs Are Me
TomCrump's Avatar
Traverse City, Michigan
Joined Dec 2005
11,554 Posts
I build the sides, and then use the jig when I join them.
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Old Dec 21, 2011, 10:12 AM
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United States, VA, Forest
Joined Nov 2009
277 Posts
Quote:
Originally Posted by jbswear View Post
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?
I have a set of the jigs (rectangular boxes) that I would let go pretty cheap since I use a magnetic building board now. Send me a pm if you are interested.

John
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Old Dec 21, 2011, 10:37 PM
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Mooney_Driver's Avatar
USA, WA, Ellensburg
Joined Mar 2004
206 Posts
Quote:
Originally Posted by CADGURU View Post
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.
I see adjusto-jigs come up on here often. The price is usally not cheap though but the ones that show up on ebay seem to be gold plated judging from some of the prices! You did a great job on your fuselage jig. It is interesting to see all of the variations and jig designs show up. I have seen several ads in old magazines (that I never noticed at that time) which no one ever seems to have heard of and must not have been around long but jigs like yours and its variations have stayed the test of time.

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:
http://www.brotherhoodofthering.info...sts=83&start=1

and it is quite a variation but he did an excellent job.

Thank you.
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