Indexed Adjustable Pocket Screw Jig

thingiverse

I took the excellent design from roklobster04 since I wanted a bolt-down jig instead of just a clamp-on. I modified a few things: 1. Indexed the sleeve for 3/4", 1", 1.25" and 1.5" width of stock. This is on the back of the sleeve labeled 3,4,5,6 (as in quarters of an inch). All the way down is 3/4" and all the way up is 1.5". The height and placement of these is calibrated against a Kreg jig in my shop. 2. Changed the vise plate to accommodate a washer and either a bolt head or thread-locked nut behind the aluminum clamp plate. This moves the vise plate back and forth as the screw is turned. 3. Changed the knob to take a nut and washer that secures the knob to the shaft. 4. Modified the jig to use one slot-inserted nut in the base instead of two (one on each end) because I had trouble getting the shaft to cinch without a lot of backlash. The fit was very tight when printed in ABS and I modified the gaps, adding about 0.5mm for clearance on sleeve and vise mating surfaces. The original design included all the hard work of the basic setup, and I was just able to tweak it a bit. The original design used an aluminum plate countersunk to take a screw and fastener on the back side of the plate. 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, but not yet tried McMaster-Carr flanged sleeve bearing number 9440T54. Will update after they arrive. Update: The McMaster-Carr bearings arrived and fit perfectly in the jig. Attached with some CA to keep them from slipping out and did several test holes, all with great results. Tip: Set the depth collar on the drill bit by first putting a 1/8" spacer on the bottom of the jig. Then drop the drill bit in and tighten the collar with the bit resting on the spacer.