G'day Karl and fellow Patreons
I started fabricating Karl's 'J Rail design for the Floor Section and Seat Base and wondered how I could achieve it with just a hand router. So I designed the following parts to use after 3d printing them as router guides use a 12mm Follow Cutter. The Corner Radius Guide is for the Seat Base which accurately places the hole at each corner for the Swivel Truck Assembly. I will refer to the 2 small stops seen below as 'Edge Stoppers' which fit into the various Guide which ensures when clamped are flush to the edge of the panel.
The stoppers shown above are removed and inserted. Once the Guide is clamped down these are removed and gives the full outer edge for the router to follow.
I also made a Guide so the multi radius corner section could be done in one go. Again utilising the Edge Stoppers accurately getting the Guide flush to the edge. Same process clamp down, remove the Edge Stoppers for the router to follow unimpeded.
Finally the J Rail Guide. This was printed in 2 parts but was designed so each overlapped along the straight section and using some dowel posts and holes aligned the 2 parts together accurately, then simply glued them together creating a single solid guide.
Some strengthening sections outside the slot also stopped any flexing from the pressure of the router once screwed down to the floor section where clamps were unable to be used. This worked very well and was happy with the result. The router cut all 4 slots accurately and were all aligned to one another.
The 'Edge stoppers' were only used to position the initial front inner slot on the floor base. The plugs were used to accurately align the seat base in the slot Guide and allowed the other 3 holes from the seat base to be drilled into the floor. The floor base was then moved to the retracted J end of the guide and again the other 3 holes were drilled into the floor base from the seat base holes. Once these were done it was a simple process to put a plug in both holes for each J slot which then aligned the Guide screwed and clamped down then plugs removed and slot routed out. Repeat same process for remaining slots.
End result all slots were aligned with one another accurately and the trucks once assembled followed the slots without showing any binding at all.
If anyone would like these STL files happy to share just message me
Hi Ross
Just looking to start printing these out but only the Gcode files are on the download page no STL's also no file for the Edge stoppers can you help
Very helpful Francis, I also only have a hand jigsaw, will see how that goes. But as said, still some time to go for me.
Thanks for sharing. Will look at it tonight !
Hi Gunter I have completed the J Rail floor/ Seat Bases where I designed a set of router template guides which worked very well and sent the Gcode for them to Karl who graciously added the print files on his website. I also have done a step by step pictorial using them which is quite straight forward. I sent them through to Karl but not sure if he has added them or where.
Here is a link to several pictures of the templates anyway (https://www.737diysim.com/forum/product-feedback-mods/j-rail-build-router-guides/p-1/dl-61ffff78827d9400179e7549?commentId=61ffff78827d9400179e7549&origin=notification&postId=619c446935844c0016dab88e)
You can download the router templates from <Downloads><3D Printables - 737 Hardware (STL)> section
When I finished the bases I wondered also how they were meant to lock the seat base and I designed a simple spring loaded locking pin with a small Lift Lever using a large screw bolt + Nyloc nut (this requires some machining through the center of it for a Socket head screw and spring to fit inside in a clearance hole. The Bolt locks in place on the seat base with the Nyloc and the socket head screw under spring tension drops into drilled hole positions in the floor base locking the seat in place. The Socket head is lifted up with the lever to clear the base and allows the seat to slide in the J Rail Slots to whatever position is required.
Just waiting for Karl's release of the Seat built so I can work out the best position to mount it.
Hello all,
Anybody already finalized this design ? It looks neat but I would like to see how people integrate it into/onto their Base frame before I start building my base frame.
Secondly also wonder how you lock the position of the chair. Put a "tooth cam" and on the seat a spring operated lock or something ?
Not so urgent, as I have several other projects going on (servo started (cool !), MTQ, Overhead, ...) ;-)
Kind regards,
Gunter
Ok will do email replied to re same thanks for your support and help as I never thought I would be doing anything like this at this stage of my life but absolutely loving getting back into doing old trade engineering Toolmaking Fitting Machining and even Fabrication which indeed is hugely to your inspiration my friend take care
Regards Ross - Australia
Good morning Ross, I don't think downloads work on the forum. Can you send the document to me via email. I will add it to the hardware download page and any other files you want to add. We are at v2 on the webpage, this will make v3. I have also shifted it up the page so its easier to find.
I will then link the zip file to here. Thank you for all the effort you have put into this. It really does take a while to get everything sorted ! Much longer than people think.
Kind Regards Karl
If it helps others in their builds no worries Karl will send the STL's through
Hello Ross, Wonderful job! and amazing quality prints! Would you like me to share these on the STL downloads page? Kind Regards Karl