Pete's Projects

1. Decide on your dimensions.

The jig pictured has a length of 500mm, and the cross arms are 250mm each.

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2. Mark out a pair of holes on the cross rails, the position is up to you, the jig shown has a set of holes 30mm and 75mm in from each end. There hole size can be 6 to 8mm, just be sure they are drilled on centre.

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Be sure to de-burr all holes and cuts, a quick sand with very fine sandpaper, and a polish is a good idea.

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I recommend using a step drill as it's designed for drilling thin material.

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3. Mark a centre line on both the cross rails, then by eye position the slide block over the centre. 

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4. drill a 3.2mm (number 30) hole for the pop rivet. Pop rivet one side and then drill and pop rivet the other. ( one rivet each side is fine, but you can fit a pair of rivets per side)

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Assemble the two ark side panels onto the pedestal, and then slip this assembly onto the 19mm aluminium long bar.

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Making sure that everything is flat on the workbench drill, and pop rivets one end hole. Then turn around and do the same to the other side. 

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Now do the same to the opposite side, there follow on with the other 4 rivets.

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A tip.

Use a sharp no.30 pop rivet drill bit, and a low speed drill setting.