My solution to extrusion corners

[Dusty.House]

Hi all - I thought I’d share my solution for cleaning up aluminum extrusion corners. I designed and printed a cap that covers the sides but still allows access to the tracks for clamps.

I’ve seen this debated a bunch but most of the solutions required milling the aluminum.

These corners are joined with anchors but brackets will also work.

This just slots into place, after taking an hour to print

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[supimeister]

Brilliant!

But... one hour!!  [eek] [eek]

I know that 80/20 and Faztek's target market is not woodworkers, but the potential is limitless in woodworking (in jigs, workspaces, etc.)... Thanks for continuing to innovate!

 

[Dusty.House]

Brilliant!

But... one hour!!  [eek] [eek]

I know that 80/20 and Faztek's target market is not woodworkers, but the potential is limitless in woodworking (in jigs, workspaces, etc.)... Thanks for continuing to innovate!

Yeah 3D printing is not quick, but once I have it working I can do a batch over night.

I did propose the idea to Faztek, I might reach out to 80/20 if they don’t bite

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[DynaGlide]

As someone who hasn't worked with 80/20 can you dumb down why this is so important?

I'm missing something here. .I'm sure it's wonderful but I don't see how this prevent the need to mill the slots. Do the joints typically butt up not leaving room for clamps?

 

[Cheese]

I think it's just a matter of cleaning up the ends of the 80/20 profile for a cleaner look. Kind of like putting on a bed spread instead of just using a down comforter.  [big grin]

 

[Dusty.House]

As someone who hasn't worked with 80/20 can you dumb down why this is so important?

I'm missing something here. .I'm sure it's wonderful but I don't see how this prevent the need to mill the slots. Do the joints typically butt up not leaving room for clamps?

Yeah typically you butt them up together which blocks access to one side. One solution is to mill open the closed track to allow the clamp to drop in.

Also the standard cover blocks the exposed track from being used. So you might choose to mill that open to.

Or you can stagger them like this but the standard cover won’t cover the end. This leaves a sharp edge and the extrusion is hollow so it fills with rubbish!

I think this solves that issue but I’ll know for sure when I install them in my MFT this weekend

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[Bob D.]

A plus I see is the cover removes all those sharp edges which sooner or later you will catch your clothing or you hand on and wish you had installed the covers.

 

[DynaGlide]

Thanks [member=67145]Dusty.Tools[/member] for the explanation. One of these days I'll get into 80/20. . .too many other things to do

 

[nvalinski]

Very nice. I've often thought about having a similar cover printed for when I eventually get around to making a similar table, but allowing for three way access on a corner like this (original credit to Richard/RMW).

 

[Dusty.House]

Very nice. I've often thought about having a similar cover printed for when I eventually get around to making a similar table, but allowing for three way access on a corner like this (original credit to Richard/RMW).

Oh I definitely took inspiration from Richard!

His solution is really neat but I don’t have his milling skills

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