Achieve perfect joins on your DIY flyscreens with this custom-fit mitre box. Most off-the-shelf boxes are too wide for slim aluminium profiles, leading to blade wander and gaps. This jig is precision-modeled for a snug fit on Pillar 25mm frames, ensuring your hacksaw stays exactly where it needs to be.
Quick Start Guide
- 90° Cuts: Align the tool edge 10mm from your cut line.
- 45° Cuts: Align the tool edge 20mm from your cut line.
- Setup: Firmly clamp the jig to your workbench. For the cleanest results, use a second clamp to secure the far end of the aluminium frame.
Print Recommendations
- Walls: 4 walls (Recommended for better guide-slot stiffness).
- Infill: 15% Gyroid or higher.
- Note: This is a sacrificial tool. The plastic will wear as the saw passes through. For large projects, I recommend printing 2 or 3 copies to maintain precision.
⚠️ Safety & Liability Waiver
By using this file, you agree to the following: This 3D-printed tool is provided as-is for hobbyist use. 3D-printed parts can fail or wear unpredictably. The designer assumes no liability for any injury, loss, or damage caused by the use or failure of this jig.
- Risk: You assume all risk associated with cutting tools and metalwork.
- PPE: Eye protection and gloves are mandatory.
- Inspection: Check the jig for wear before every cut. If the guide slots are widened or the base is cracked, discard and print a new one.
- Alternative: If you are uncomfortable with these risks, please use a professional steel mitre jig or hire a qualified contractor.
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