Vacuum-Clamped Handle Routing Jig

Handle Routing Jig with Vacuum Clamping

This is the last part of my vacuum clamped routing jig trilogy to cover all major use cases. With the latest addition it is possible to mill cutouts for manual handling super-safely & accurately, similar to the models I released earlier focusing on corner, chamfers and skirt board cutouts.

Vacuum-clamped handle router jig	Vacuum-clamped corner radius & chamfer router jig (metric / imperial)	Vacuum-clamped skirt board router jig

Please also see my other vacuum tools and clamps in this collection.

Features

• Included in this set
  • Vacuum-clamp module to hold the inserts
  • Inserts for handle cutouts:
    • 120 x 30 mm
    • 100 x 25 mm
    • If you need other dimensions, please leave a comment! I will add more over time.
• Inserts include special indicators to accurately position on the center axis (horizontal and vertical)
• Application for handheld routers (not suitable for stationary router tables)
• Vacuum-clamp module with large base to allow for usage with larger routers or router bases, e.g., for the Festool MFK 700

Usage Instructions

• Step 1: Position jig using the special indicators on the insert, mark contour with a pen, remove jig, pre-drill and pre-cut with a jig saw while leaving 1-3 mm material for the routing step
• Step 2: Re-position jig again, clamp via vacuum
• Step 3: Mill the handle cutout using a flush trim router bit with top bearing
• Step 4: Remove jig

A picture documentation is available for the similar concept jig for routing cutouts for skirt boards 

Instructions

• Print using the profiles
  • Main router jig
  • Inserts
• Screw in the fitting
  • Be gentle, no need for extra force, not needed to screw in entirely, ideally use an Allen key instead of a wrench to for better alignment
  • Optionally soften the material with a heat gun or torch prior to screwing in the fitting to reduce the risk of layer separation
• Mount the seal (cut to length and glue with PA glue; I recommend cutting in 45°)
• Attach a vacuum pump and you are ready to go

Additional hardware required

• 5 mm foam seal, e.g.,
  • https://amzn.eu/d/dGv3wjv as a cost efficient version (works perfectly well but a bit harder to mount)
  • https://amzn.eu/d/6fLlTmm a bit more expensive but easier to mount
• PC6-01 pneumatic fittings (e.g., https://amzn.eu/d/fOVNi5r)
• Useful starter set including pneumatic fittings and tubes (e.g., https://amzn.eu/d/br2hIfl)
• CA glue for closing the foam seal
• Vacuum pump
  • I would recommend a strong version with 500+ Watts if you are planning serious work like clamping for sanding or routing. I am the using this one.
  • If you want to try it out and have a fun project, you can build the smaller Filament Vacuum Pump (I would not recommend it for this use case as it might be too weak but is great to create a filament vacuum for storage)