I decided to build the majority of my jig using 80/20 brand extrusions. There are a variety of aluminum extrusions available, Arctos jigs use Item
Because many bicycle dimensions are given in metric, and I think it is a better system, I went with Metric extrusions. I went with the 40 series metric extrusions.
A little information I learned about 80/20:
80/20 comes in a variety of metric and SAE sizes. Their naming system give the distance between channels on all extrusions in that series. For example metric 40 series is 40mm between channels and the 1.5 series (the approx. metric equivalent to the 40 series) is 1.5 inches between channels. The individual extrusion options are named for their dimensions. 40-40 (the skinniest option in the 40 series) is 40mm x 40mm. It has one channel in the center of each face (20mm from each side). The 80-40 series is 40mm x 80mm. The 80mm face has two channels and the 40mm face has one channel. Each extrusion series is designed to use a specific hardware. 40 series is made for M8 bolts. The channels take M8 bolts and the end holes are the right diameter to be tapped for M8 threading. Therefor I used almost exclusively M8 bolts for this project. Detailed CAD drawings of lots of the available 80/20 extrusions can be found on McMaster Carr
. However, McMaster did not have all the specific extrusions that I wanted so I ordered all of my 80/20 on Amazon.
See the attached .pdf of all the specific extrusions I purchased (as well as what lengths I used).
The specific parts that I milled were almost entirely 6061 aluminum. It is fairly light, fairly cheap and I had access to lots of scrap. I used flat stock from 1/4” up to 1 1/2” and round stock with a diameter of 1.5”. I also used some 3”x3” angle aluminum (1/4" thick).
Handles and Hardware:
I bought all my hardware from McMaster Carr.
I bought dummy axles from the United Bicycle Institute. Note: My Jig is designed to work with the specific dimensions of these dummy axles, modify yours if you use different dummy axles.
Tools (at least some of the important ones):
Bridgeport 1 Series Manual Vertical Mill for milling parts
Sharp Manual Lathe for making cones and BB shell mount
Omax Waterjet for cutting parts from stock
Cold saw for cutting stock and 80/20
Horizonal and Vertical Band Saws for cutting stock