Pocket Hole Jig

This thing is very usefull when you working with wood. I was thinking about buying it, but only this piece of plastic cost about 50$ and whole concept cost about 100 - 150$ and I think it's pretty much for this. So I decided make my own.

Step 1: 3D Print

First download 3D model from this page: Page for download, or you can make your own ;) .

After printed, It is good to coat it with acetone to make it more solid and stronger.

Step 2: Materials

What you'll need:

1. 3D printed model.
2. Piece of aluminium profile or another base.
3. Piece of "L" shaped metal sheet.
4. Toggle Clamp (link)
5. Pipe
6. Nuts and bolts
7. (Glue)

Step 3: Inserting Pipes

Because of the 3D printer are not too accuracy, the holes are little bit different. They are about 11 mm diameter.

After cut two pieces of pipes, warm it with blowtorches or gas cooker like me and insert it into plastic model.

The holes are little bit deformed from hot pipes, but It's only on the top and it doesn't matter.

Step 4: Grinding

After inserted pipes, you must to grind it to make it flat. I used abrasive disc on angle grinder, but you can also use saw or something else.

Step 5: Base

Add L metal sheet like support for jig hole.

Step 6: Toggle Clamp

Add toggle clamp against L shaped support, that attaching wood. Because I used this aluminium piece like base I can move this clamp according to thickness of drilled wood.

Step 7: Attaching Jig Hole to Base

This step is optional. I glued the pocket hole, exactly on L shaped support, with silicone glue. To hold it during glueing I used toggle clamp.

Step 8: Upgrade

I edited it and make it like this.

When pocket jig hole was completely down, there wasn't much space for drill bit. I edited also toggle clamp and put it little bit higher because wood had tendency leaning to clamp.

Step 9: How It Works

It works pretty well, one problem I have is my short drill bit :D But if i drill outset of hole, then I can easy drill it without pocket hole jig. But I will buy longer drill bit definitely.

Comments

[gm280]

Pocket holes are an amazing way to fasten wood projects together. Not only does it hold tight, it holds strong as well. I use a Kreg Pocket hole jig assemble because I was gifted such a jig as a present. It works great and they have replacement parts and step drill bits as well. If you are building cabinets, there is no better way to fasten them solidly together. Apply a little glue and screw it tight. Never coming apart again.

[Yonatan24]

If you are building cabinets, there is no better way to fasten them solidly together.

...What? https://www.youtube.com/results?q=matthias+wandel+... :)

[gm280]

I stand corrected. After watching the videos, there is a stronger way. However, I usually don't hang on my cabinets and thus far they have stayed tight and work well. But there is a stronger way to make the cabinets as I now see. Thanks for the reply and new info.

[Yonatan24]

All of Matthias' subscribers know that pocket holes are EVIL!

(Though they are cheaper, quicker, and easier to use than a Pantorouter!)

[mtairymd]

But Kreg has "independent testing" that shows the joint is 35% stronger than the comparable mortise and tenon joint :).

http://www.rockler.com/how-to/pocket-hole-joinery-...

[Yonatan24]

Depends how they make the mortise and tenon... :)

[Dui ni shuo de dui]

Hehe, actually they are not too bad, it just depends on what you are looking for.

For example, if you want to build something quickly and it doesn't need to be incredibly strong, then pocket holes are a great choice. If you are going for super strenght and don't bother spending much more time on a projects, then other types of joints, like mortise and tenon, box joint or dovetails are better. Anyway, pocket holes are still way better than simple butt joints and, I guess better than biscuit joints. BTW, you don't need a pantorouter or any fancy tool to do a mortise and tenon, it can be done easily with only one wood chisel.

I assume it is even faster with the chisel than using the pantorouter if you only have one or two joints to do (I suppose that it takes time with the pantorouter to set up exactly and accurately the cutting position, as Matthias says in his videos that he often has to do several trys with scraps to make a perfect fit).

[rafununu]

It seems there's a better way...

[mtairymd]

Cool project and nice job!

I've used this tool on multiple projects and I'm very happy with the results. As pointed out below, strength of the joint could be an issue. One should take this into account if a significant load will be taken across the joint.

For future reference, you can buy the Kreg knockoff from Harbor Freight for ~$52 ($65 - 20% coupon).

http://www.harborfreight.com/portable-pocket-hole-...

[krieglers]

very nice idea, I will definitely build one. I may though use brass tube, as a modeller I have quite a few the inner diameters are more precise and they have thinner wall thicknesses. I also would probably not heat the tube, as it's easier to file some teeth and then use a drill to cut and insert the tube.
love the idea, I will build one when back at home in the new year.