Greg Guarino wrote:


I finally got around to drilling the pocket holes this evening and I
have to say the makeshift jig worked like a charm, surely cutting the
job down by at least half, more likely 2/3. Except...

That's great Greg. Always good when a plan comes together.


[there's always an "except..."]

It turns out that I blocked a small portion of the chip-escape holes
when I made the jig. It didn't seem like a lot visually, but the chips
built up and caused some slight burning in the first two holes I
drilled. I should add that I was also using a more powerful drill than
in had in the past..

Hmmmmm... I wondered about exactly that when I built my jigs. I routed
escape areas in my jigs because I was afraid the walnut would not hold up to
clamping if I cut in channels the way the Kreg does in their jigs, and I
haven't tested them yet so I'm a little curious now. I can always route
mine deeper if I need to (actually - I'd have to chisel them now...)


So, to my makeshift "jig", I added an even more makeshift chip removal
"system", shown below. [those with frail constitutions or firmly-held
notions about doing things the proper way strongly cautioned ]


Hell Greg - looks great! It has that "prototype" look about it that all
good products start out with.



Believe it or not, this worked pretty well. The vents stayed clear,
the drilling was easier, and the holes didn't look burned.

The "system", even as hastily conceived as it was, allowed me to speed
through the task with confidence. And it has given me ideas for a more
permanent jig that I'll eventually build. I wonder now if that's not
the usual way such things are done: Rather that try to perfect a
device in theory, build a quick first attempt and use the lessons
learned to improve the permanent model.

Yup - the very definition of a prototype.


Of course, "temporary" stuff can have a surprisingly long lifespan in
my house.

You mean there is a different way?

--

-Mike-