Jig creation manual for use in BDV designs

From

Big Deal Volumes

jig creation instruction manual

This Manual is published under a Creative Commons, Attribution Non-commercial license.

(https://creativecommons.org/licenses/by-nc/3.0/us/)
Anyone can use it, Anyone can modify it, Anyone can have it.
No one can profit from it.
Disclaimer: Climbing is inherently dangerous, and so are power tools. Do not attempt to construct
anything in this manual without proper training or safety precautions. Doing so can result in injury or
death. The methods and design laid out in this manual are not a certification of integrity, that is up to
you and your construction.

Table of Contents
Jig creation manual for use in BDV designs.............................................................................................. 1
Laying out & cutting out the plywood panels............................................................................................3
Laying out the jig....................................................................................................................................... 4
Sanding.......................................................................................................................................................5
Finishing.....................................................................................................................................................6
Clean up & Touch up................................................................................................................................. 7
References:.................................................................................................................................................8
Required Materials:....................................................................................................................................9
Required Tools:........................................................................................................................................ 10
Helpful tools:............................................................................................................................................11
Estimated cost breakdown:...................................................................................................................... 12
Credits:..................................................................................................................................................... 13
Contact US............................................................................................................................................... 14
BigDealVolumes@gmail.com ............................................................................................................ 14
https://www.facebook.com/BigDealVolumes..................................................................................14
https://www.reddit.com/user/Bigdealvolumes................................................................................ 14
http://routesetter.org/forum/index.php.............................................................................................14

jig creation instruction manual

Laying out & cutting out the plywood panels.

Measure twice, cut once.

This layout accounts for a full width (1/8in.) table saw blade.
The rest of the piece of plywood is not used in this manual, but in other manuals the crossed out
section of plywood is used to create other pieces.
The factory edge on the jig is only a problem if you cant accurately and consistently make
measurements off it. Use your best judgement if dimensions can be measured accurately off the
edges.
If necessary, trim the jig 1/8 in. so one corner (the lower right in this photo) is square,
and offset the holes by an 1/8 in. If you purchase your plywood from Lowes or Home
Depot they may do this for you if you ask nicely.

jig creation instruction manual

Laying out the jig

The jig can be a great aid in construction if laid out correctly, take your time and get it right.

Ensure that you are not drilling where a t-nut wont fit.
When in doubt, don't drill. You can always drill it later.
Don't use a spade drill bit, they tend to chip plywood unless you are careful.
A good way to prevent damage to the wood surface is to use a piece of scrap wood on the pack
of every hole you drill, just dont drill your hand.
This design assumes the following:
the hole will be drilled with a 7/16 Forstner bit

jig creation instruction manual

Sanding
Sanding the Jig is not completely necessary, however it gives you a good surface that is free of
blemishes that could adversely effect other panels that you clamp to the jig later on.

The first step in getting a good finish is to sand a very long time and do it very well.
A handheld rotary sander is a good investment for all projects and will save you time and effort.
Sand down the sharp edges with 60 grit paper.
Keep sanding and reducing the grit when applicable from 60 to 80 to 150 to 220 grit.
After you are satisfied that everything is smooth and shaped the way you want it, move on.

jig creation instruction manual

Finishing
To prevent the plywood from warping (unlikely) you should apply some wood sealant to all the
surfaces and sides of the jig.
Finishing the jig is not a completely necessary step, but if you want a clean even surface to
construct with, then a non latex based paint is advised.

jig creation instruction manual

Clean up & Touch up

As a final step and to make the jig last longer, put a very thin layer of high strength epoxy
around the insides of the drilled holes. It may be a difficult job but with your pinky and a rubber
glove it can be done.

jig creation instruction manual

References:
Human exertion limits
http://msis.jsc.nasa.gov/sections/section04.htm
Plywood structural references
http://apawood-europe.org/wp-content/uploads/2013/07/PS-1-09-+APA-trademarks.pdf
T-nut pull through testing data
http://www.agriculture.purdue.edu/fnr/faculty/eckelman/documents/d199856a.pdf
Wood screw technical report by the Forest Products Lab of the US federal government
http://www.fpl.fs.fed.us/documnts/fplgtr/fplgtr190/chapter_08.pdf
Tiebond III Glue information
http://www.titebond.com/product.aspx?id=e8d40b45-0ab3-49f7-8a9c-b53970f736af
Tiebond III Glue MSDS
http://www.franklininternational.com/msds/1413.042m0fao0020.pdf

jig creation instruction manual

Required Materials:
in x 4ft x 8ft plywood
http://www.lowes.com/pd_75514-99899-75514_0__?
productId=3658448&Ntt=3%2F4in+4ft+8ft+plywood&pl=1&currentURL=%3FNtt%3D3%252F4in
%2B4ft%2B8ft%2Bplywood&facetInfo=
Optional finishing supplies as you see fit:
West systems epoxy (http://www.westsystem.com/ss/product-selection-chart)

105 Epoxy

207 Hardener

406 Additive silica

barcoat (http://www.bestbartopepoxy.com)
latex spray paint (any brand as long as you prep the wood as instructed)
Minwax system finish:
Always apply in this order (top first):
Wood conditioner (http://www.minwax.com/wood-products/preparation/minwax-water-basedprestain-wood-conditioner)
Water based wood stain (http://www.minwax.com/wood-products/stains/minwax-water-basedwood-stain)
Polycrylic protective finish (http://www.minwax.com/wood-products/clear-protectivefinishes/interior/minwax-polycrylic-protective-finish)

jig creation instruction manual

Required Tools:

10

A table saw, or circular saw.

A drill; a drill press is great, a hand drill works just as good

7/16 forstner bit (http://www.amazon.com/Steelex-D2847-Forstner-Bit-16Inch/dp/B0000DD32P/ref=sr_1_2?ie=UTF8&qid=1421521447&sr=82&keywords=7%2F16+forstner)

All the safety equipment any product recommends.

Tape measurer at least 12ft

jig creation instruction manual

Helpful tools:

Drill angle guide, makes drilling angle, complex and perpendicular holes so much easier.
http://www.homedepot.com/p/General-Tools-Drill-Guide-and-Chuck-36-37/100349264?
keyword=angle+drill+guide

Power sander, (damaging you shoulder making a climbing volume seems kind of silly.)
http://www.homedepot.com/p/Ryobi-2-Amp-1-4-Sheet-Sander-Green-S652DGK/205179523?
N=5yc1vZc29d

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jig creation instruction manual

Estimated cost breakdown:

Rounded up and not including more expensive power tools.
in x 4ft x 8ft plywood

50$

7/16 forstner bit

6$

All the safety equipment any product recommends.

Safety glasses

3$

Eye surgery

5000$ min

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jig creation instruction manual

(Use safety classes)

Credits:
Design by: Jace W.
Special thanks to :
Carolyn L

13

Jason L

Karynne C

jig creation instruction manual

Contact US
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An idea?

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Feel free to send feedback, comments, questions, or requests to:

BigDealVolumes@gmail.com

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This manual is published by Big Deal Volumes as part of the DIY collection.
More to come.

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From MT. With love.

jig creation instruction manual