Hexagon Sled/Jig

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Project by Bags posted 10-09-2013 11:02 PM 5850 views 20 times favorited 21 comments Add to Favorites Watch

I needed to make 400 wooden “nuts” to fit on wooden threaded “bolts”. The nuts needed to be a hexagon shape, have a 3/4 inch threaded hole in the middle and be 5 cm from one parallel side to the other. In order to cut them as efficiently and safely as possible, I came up with this sled. Hopefully my description below (along with the pictures) makes sense.

What I did to build the sled:

1) Calculated all the angles and lengths that were needed ( I had to dust off my old high school trigonometry book to do it but…)
2) Laid out the needed measurements on the jig bottom board
3) Installed individual fences on the jig bottom board – each fence separated the wooden blanks from each other and held the blanks at the proper angle (60 degrees) to the blade when the board was pushed through the saw
4) Installed short dowels to hold each wooden blank the correct distance from the blade and kept the blanks from moving along the jigs internal fences when the jig was pushed through – each wooden blank had 5/8 inch hole drilled in them
5) Installed a jig top board to keep the blanks from moving up and down

How it works:
1) Load the sled with blanks
2) Push both sides of the sled through the saw (the sled’s width gave me a good deal of safety)
3) Take the top board off and rotate all of the blanks around the dowel. Replace the top board
4) Continue to cut and rotate until all sides are cut.

The sled held 14 blanks at a time. The total time cutting 400 blanks was still measured in hours but I think it worked out pretty well. It was safe and I was able to “tile the plane” with the finished product.

21 comments so far

View AlBCuttnWud's profile


734 posts in 3751 days

#1 posted 10-09-2013 11:23 PM

I would have burned a few brain cells to get to that. So what are you going to do with all the nuts?

-- -Al, Jacksonville, FL

View HillbillyShooter's profile


5811 posts in 3354 days

#2 posted 10-09-2013 11:24 PM

Very clever—congratulations on a neat solution for multiple repetition in parts production.

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View hoss12992's profile


4180 posts in 2954 days

#3 posted 10-09-2013 11:39 PM

This is really cool and very creative. Great job

-- The Old Rednek Workshop

View Palliserwoodsman's profile


33 posts in 3702 days

#4 posted 10-10-2013 12:24 AM

This is sooooooo cool

-- Owen, Lethbridge, Alberta

View gpastor's profile


192 posts in 4120 days

#5 posted 10-10-2013 01:24 AM

400 nut. That’s just nuts

-- Gray hair is a crown of splendor; it is attained by a righteous life. Proverbs 16:31

View BusterB's profile


2311 posts in 3070 days

#6 posted 10-10-2013 02:52 AM

That is an impressive jig….nice work.

-- Buster, Ocoee TN (Critics are men who watch a battle from a high place then come down and shoot the survivors - Hemingway)

View oldnovice's profile


7702 posts in 4429 days

#7 posted 10-10-2013 06:03 AM

One more time, 400 nuts is just … what on earth for?

I like math problems and your solution!

-- "It's fine in practise but it will never work in theory"

View jeffswildwood's profile


4878 posts in 3039 days

#8 posted 10-10-2013 12:30 PM

As woodworkers we run into very interesting problems to solve. You nailed it on this one! But I’m with everyone else, 400 nuts? And I noticed also 400 bolts! I guess the bolts could be done the same way by removing the dowels and drilling holes in the top board to prevent movement. Hope you post what this going to be!!

-- We all make mistakes, the trick is to fix it in a way that says "I meant to do that".

View Andy's profile


1713 posts in 4970 days

#9 posted 10-10-2013 12:43 PM

I am totally impressed.
I am saving this for future reference in case I need to make lots of octagons.
Very clever and you explained and photographed this well.
Thanks for sharing.

-- If I can do it, so can you.

View 308Gap's profile


337 posts in 4064 days

#10 posted 10-10-2013 03:51 PM

Thats just NUTS!

-- Thank You Veterans!

View stefang's profile


17040 posts in 4396 days

#11 posted 10-10-2013 04:52 PM

Great jig both for the cutting and the safety.

-- Mike, an American living in Norway.

View SheriDi's profile


147 posts in 4365 days

#12 posted 10-10-2013 05:50 PM

Very impressive! Congratulations.

-- A Veteran is someone who, at one point in their life, wrote a blank check payable to the United States of America for an amount up to and including their life. That is beyond honor

View MrRon's profile


6014 posts in 4305 days

#13 posted 10-10-2013 06:27 PM

What a great example of thinking outside the box.

View Michael Wilson's profile

Michael Wilson

588 posts in 3552 days

#14 posted 10-10-2013 08:12 PM

Nice! I’m guessing this idea would adapt really well for making complex shape composite cutting boards.

View tyvekboy's profile


2111 posts in 4075 days

#15 posted 10-11-2013 01:36 AM

Great Jig.

-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

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