Gas station without pumps

2017 September 27

Jig for drilling Lego bricks

Filed under: Circuits course — gasstationwithoutpumps @ 15:07
Tags: , , ,

For the pulse-monitor lab, I have students drill ⅛” holes through 1×2 black Lego bricks (see Lego as LED holder and Lego as LED holder revisited), to make holders for 3mm phototransistors and 3mm LEDs. I hauled my drill press up to campus in my bike trailer last year to have students drill their own bricks, but I was not happy with the plywood jig that I had put together at the last minute—it worked, but there was a tendency for the bricks to jack-knife when the drill press vice was closed, because I had a sliding piece to clamp the brick.

I redesigned the jig yesterday and came up with a much simpler and (I think) more reliable design:

This side view shows the jig cut out of a piece of polypropylene cutting board that had been retired from kitchen use as too beat up. The bottom edge is straight, and the top edge has a rectangular cutout exactly the width of a Lego brick. (The top edge is not flat, because it was cut from a part of the cutting board that had a handle.)

Here is a top view of the jig in the drill press vice. In classroom use, I’ll probably use some painters’ tape to hold the jig to the non-moving jaw of the vice.

To use the jig, open up the vice a little bit, snap the brick into place, and tighten the vice gently to hold the brick securely. The cutting board is just a little thinner than the height of the brick, so the clamping force of the vice is entirely on the brick.

I may add these photos to my book.

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