- Made the phenolic slide pieces on F13 (photo 1, x2)
To make the slot I cut a row of holes with the drill press. You can't get the holes to overlap (the bit just slips off sidways), so I just got close, and then used a utility knife to cut the remaining areas between 3 of the holes at one end. I then clamped the piece horizontally in the vice. The connected holes gave enough room to now slip my jigsaw blade in there and CAREFULLY cut the slot by connecting the holes and then CAREFULLY shaving away at the sides of the slot until it was reasonably straight and close to the layout lines.
Then I did a lot of hand filing with small flat and curved files to get the slot smoothed out and to the final width. Phanolic is hard stuff, so it took a fair bit of filing to get it done.
- Pilot drilled into the angle and held in place with long-reach clecos and clamps
- Countersunk the screw heads and secured with washers and nuts
