Used for drilling blind holes, in matched faces, for dowelling metal or wood assemblies.

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125mm x 127mm x 15mm 5083 Aluminium Plate

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Glued on cad template (link below)

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Optical centre punch (link below)

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Centre drilled used as fluffer (minimizes deflection) prior to pilot drilling

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Pilot drill all holes 3mm

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6mm drill

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Cut out profile

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Filed. A good selection of files helps; the dreadnought type is especially good on aluminium.

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Cleaned up a little more

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…and a little more

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Homemade edge chamferer/deburrer from an old three square file

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Drilling ready for threading m12 inserts

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Threading

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Countersinking

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Inserts: centre drilling

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Countersinking a relief to stop the slot in the screw snaping the twist drill used in the next operation

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Drilling to finish size

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Stamping sizes on the heads (there are 5 different sized inserts in my set)…

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Inserts fit nice…

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Insert needs to be below the surface on both sides

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Main body finished & inserts finished.

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Marking out the fences for the tool

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Cutting the parts

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Drilled, tapped,assembled to slider blocks and lapped flat

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Wallop….

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Underside

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knoba – Adjustable Dowel Jig – 2015.dxf (link below)

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knoba – Adjustable Dowel Jig – 2015.dxf

knoba – Optical centre punch

knoba – Dewalt chop saw mods

Wiki – 5083 aluminium alloy

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