Sunday, October 25, 2009

How to use Templates.

Paper templates are attached to material with scotch tape. Adhesive labels can be used instead, they are faster to apply, but plain paper scotch tape is faster.

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1. Print out the template. Compare printed ruler with a measuring tape (both X and Y) - if the error is significant (≥1/32" per 6"), try scaling the page up/down in the print settings.

Puncture the hole centers with a needle or a push pin. Try to get exactly in the center - these holes help to guide the center punch.

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2. Cut out the label using ruler and hobby knife along the solid lines. Score the dashed lines. Try to stay exactly on the line and be careful not to cut through.

Unless you're making lots of components, make sure the angle/tube piece is not too long - it is more convenient to work with shorter pieces.

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3. Tape one edge in several places, then tightly wrap around and tape the free edge. Also tape the corners and other places where you're going to saw. Try to avoid taping over the punctured hole centers. The edges should match up if you did everything right.

If you're using adhesive label, peel off the backing, bend the label and apply it to the angle, corner first, then sides. If it's the square tube, apply middle corner first, then inner sides, then outer sides.

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4. Place the angle/tube with the label on a sturdy surface and mark the holes with a center punch and a hammer. If you're using adhesive label, hammer strikes may shift the label if the piece is in the vise.

Using marks as guides, drill the holes in the angle. It's good to lubricate the drill bit with some candle wax.

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5. Once the holes are drilled, saw where marked and deburr with a file. Remove the template. Deburr the holes with countersink bit.

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