2022-10-06 (Th) PoweredInlineSkates Template making

The template from my CAD file used 1:1 holes, which would be perfect if I cut the material directly, but I'm making a template, so I shrunk the holes to make it easier to find the center. I added labels to make it easier to remember which size each hole should be, then cut a template from corrugated cardboard I scrounged from the recycling bin. Everything fit neatly on a 300 mm x 300 mm piece of polycarbonate. I marked all the holes and curves but only drilled pilot holes to start. I used the pilot holes to align the halves and drilled my final holes with the sides held together, so they aligned perfectly. This precaution should ensure my wheels align during assembly.
Cardboard template and parts

I bought 2040 extruded aluminum as an interface between the polycarbonate sheets and the boot, but I had to drill holes in the center that matched the boot mount spacing. I drew a template with six M5 points and spots for the 1/4" (6 mm) mounting bolts. I marked both sides of the rail and drilled my holes, and the extra effort seemed to pay off because my holes were true.
On-the-fly 2040 template

The rest of the posts for this project have been arranged by date.
First time here?

Completed projects from year 1
Completed projects from year 2
Completed projects from year 3
Completed projects from year 4
Completed projects from year 5
Completed projects from year 6
Completed projects from year 7
Completed projects from year 8

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