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The drill bit supplied was 9/32 but the holes are NOT all the same. The middle hole, which is used to bolt the jig on through the old upper caster hole is very obviously smaller than the the other 2 holes in the jig.

algale wrote:The drill bit supplied was 9/32 but the holes are NOT all the same. The middle hole, which is used to bolt the jig on through the old upper caster hole is very obviously smaller than the the other 2 holes in the jig.

Yes that is a puzzle - what did you insert into it to locate to the second 'original' hole?(note I edited 'all holes the same' post)

JPG wrote:

algale wrote:The drill bit supplied was 9/32 but the holes are NOT all the same. The middle hole, which is used to bolt the jig on through the old upper caster hole is very obviously smaller than the the other 2 holes in the jig.

Yes that is a puzzle - what did you insert into it to locate to the second 'original' hole?(note I edited 'all holes the same' post)

The caster instructions say to use one of the supplied Phillips head fasteners (machine screw?) and keps nuts. I believe the locating hole is small and makes a tight fit with the fastener to reduce play in the jig when drilling the holes. The pin is also a close tolerance fit.

algale wrote:

JPG wrote:

algale wrote:The drill bit supplied was 9/32 but the holes are NOT all the same. The middle hole, which is used to bolt the jig on through the old upper caster hole is very obviously smaller than the the other 2 holes in the jig.

Yes that is a puzzle - what did you insert into it to locate to the second 'original' hole?(note I edited 'all holes the same' post)

The caster instructions say to use one of the supplied Phillips head fasteners (machine screw?) and keps nuts. I believe the locating hole is small and makes a tight fit with the fastener to reduce play in the jig when drilling the holes. The pin is also a close tolerance fit.

So the supplied screws must be slightly undersized.(<.245)

That makes no sense since the original hole(in the leg) is larger.

The locating is accomplished with the pin. The second 'locating' hole serves to keep all 4 holes on a common center line). Slight deviation is not likely a significant problem.

In any event a tremendous improvement over previous 'debacle'(s).

Thank you for the time and effort expended. You have answered my question which was "Does the new jig differ significantly from the original template". In my opinion, it does not. Therefore, the template, if you have one, is adequate to perform a proper installation BUT only if you have the final template. There was at least one template that was incorrect.

dusty wrote:"Does the new jig differ significantly from the original template". In my opinion, it does not.

You're right Dusty. The jig makes it really simple to do though, either Shopsmith's or Bill Mayo's.

Tom

tomsalwasser wrote:

dusty wrote:"Does the new jig differ significantly from the original template". In my opinion, it does not.

You're right Dusty. The jig makes it really simple to do though, either Shopsmith's or Bill Mayo's.

Tom

As did mine for me.

dusty wrote:As did mine for me.

No doubt it's true Dusty. I know you have better drill skills than me. I always send that bit skidding around the target but the jig keeps it in place.

Tom

tomsalwasser wrote:I always send that bit skidding around the target but the jig keeps it in place.

Tom

Have ya tried putting a dimple, with a punch. On the mark ya want to drill?

beeg wrote:

tomsalwasser wrote:I always send that bit skidding around the target but the jig keeps it in place.

Tom

Have ya tried putting a dimple, with a punch. On the mark ya want to drill?

Then drill a small pilot hole and gradually increase drill size on subsequent drilling.