garageFab.cc

This page describes how to make a component part from aluminum angle or square tube using a template label. This method is used to make virtually all aluminum component parts of Contraptor. It is possible to use plain paper and scotch tape instead of adhesive labels. While plain paper requires quite a lot of taping for some components, it is easier to remove than adhesive labels. 

1. Print out the template on a full sheet label. Compare printed ruler with a measuring tape (both X and Y) - if the error is significant (≥1/32"), try scaling the page up/down in the print settings.		2. Puncture the hole centers with a needle or a push pin. Try to get exactly in the center - these holes help to guide the center punch.
3. Cut out the label using ruler and hobby knife along the solid lines.		4. Score the dashed lines. Use a good ruler to stay exactly on the line and be careful not to cut through - practice first.
5. Unless you're making lots of components, make sure the angle/tube piece is not too long - it is more convenient to work with shorter pieces. Peel off the backing, bend the label and apply it to the angle, corner first, then sides. If it's the square tube, apply middle corner first, then inner sides, then outer sides.		6. The edges should match up if you did everything right. If you're using plain paper with scotch, tape one edge in several places, then tightly wrap around and tape the free edge. Also, tape corners and other places where you're going to saw.
7. Place the angle/tube with the label on a sturdy surface and mark the holes with a center punch and a hammer. Don't put it in the vise - hammer strikes will shift the label.		8. Using marks as guides, drill the holes in the angle. It's good to lubricate the drill bit with some candle wax.
9. Once the holes are drilled, saw where marked and deburr with a file.		10. Remove the template sticker using adhesive remover and a knife.

11. Sandpaper the sides where the label was to remove small burrs left from drilling.