Modifying the Kreg Pocket Hole Jig

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Blog series by MT_Stringer updated 11-14-2013 05:52 AM 3 parts 40303 reads 12 comments total

Part 1: New Life for the Pocket Hole Jig

11-14-2013 04:48 AM by MT_Stringer | 1 comment »

Some of you have probably seen my Pocket Hole jig set up (pics shown below). It works great. I have drilled hundreds of pocket holes with it. But, therein lies a problem. When I am drilling holes in panels such as plywood cabinet members, I have difficulty reaching around or over the panel to operate the clamp. In fact, on more than one occasion, I have scraped my arm. That is not good for a guy with thin blood. So, in the words of Tim, The Tool Man Taylor “So I rewired it!” :-) I know ...

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Part 2: Designing the new jig

11-14-2013 05:15 AM by MT_Stringer | 1 comment »

Something I had on hand is a piece of 1/4 inch aluminum plate 3 inches wide x 12 inches long. I decided to mount the cylinder on it. But first, I made an exact duplicate out of 1/4 inch mdf so I could figure out how and where to mount everything. After removing the clamp mechanism that came with the jig, I commenced to measure and drill mounting holes in the mdf. I don’t have a picture, but I used the original nuts that were used to secure the clamp. I used JB Weld epoxy to pe...

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Part 3: Final Assembly

11-14-2013 05:52 AM by MT_Stringer | 10 comments »

Time to get this project wrapped up.I covered the plywood deck with white Formica as well as the material supports and the rear support for the cylinder. After trimming the laminate flush with the plywood, I used a chamfer bit to bevel the edges slightly. Now for the nitty gritty. Here is a close up of the cylinder mounted on the jig. The original four 10-24×1 inch machine screws secure the front of the plate. Two 1/4 -20×1 inch round knobs attach the rear of the plate to the ...

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