Although the output from this post benefits my model railway stuff, the subject is actually the jig. The Frem0n30 UK group require legs to hold the modules up at the same height and the easiest way of ensuring that happens is to supply them.
Using one of my own legs as a template, I bodged together a jig for mass production of the ordered legs. The 76m of 3″ x 1″ planed timber was bought from Dunwoodys in Caterham as previously and the cutting, routing and screwing began.
The jig was the same top from the chest of drawers that formed the jig used to cut down the module sides from 6″ to 4″. A lip was added to one end to butt the feet up against and alignment bars held in place by dowels to position the stretchers.
Those alignment bars were originally screwed down, until I realised that we wouldn’t actually be able to remove the assembled leg without undoing the screws! Finally, clear labels were written on insulating tape to ensure that the jig is used correctly.
Using this jig, starting with kits of parts that had already been cut and routed, two people were able to assemble 26 sets of legs in one full day. Each leg comprises two uprights, two stretchers, two feet, twenty-eight 1″ screws, two 8mm holes and two adjustable bolts. The number of legs per hour improved as work continued.
If I was in any doubt as to the value of a jig before, I’m not any longer.