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Dalrun Design

Things I've designed, make and use. The focus here is on products, items I've already designed and figured out how to make. Everything is handmade in small batches or as individual pieces. All items can be customized, some aspects for little of no extra cost. I will include anything others may find useful, regardless of price. Some items would have to be mass produced to be reasonably affordable.

I you have any questions about a particular item, or are interested in purchasing it/something like it, please use the item's comment link or let me know. I'm happy to add PayPal or eBay purchasing options.

Incremental T-slot Fences

Incremental T-slot FencesT-slot extrusions make great fences. Adding a series of holes to the bottom of the t-slot allows fence stops to be moved incrementally. All my fence stops have two pins that mate with round t-slot nut holes to square the stop to the fence. The only difference between the free sliding stops and incremental stops is the length of the pins or the addition/removal of a spacer. Useful increments/pin spacing include 1" or 25mm (imperial or metric) and 32mm for 32mm cabinetmaking. The stops can provide finer increments, e.g. 1/32 > ~.003" and 1.0 > .01mm.

I currently have new 70" 1515 extrusions available with 3/16" holes in 1", 25mm and 32mm increments. While I use a fixture with a .01mm/.0005" increment DRO, the resulting distance between any two holes can vary by as much as .1mm/.004". All holes are drilled and reamed to .1890"
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T-slot Toggle Clamp Bases

T-slot Toggle Camp BasesFirst up is a 2 x 2 x 1/4" base for mounting 102-B toggle clamps to 15 series extrusions. The clamp can be mounted inline with the extrusion, or perpendicular to it. When perpendicular, it can be aligned with the front or back of the extrusion. The knurled screws make the clamp easy to move and reconfigure. The t-slot nuts are 3/8 stainless and all mounting screws are m5 (a hair bigger than #10-32) stainless. Two available. $32 each set. All sets include 1 base, 1 t-slot nut, 4 clamp mounting screws and 2 knurled base mounting screws.

The smallest 102-B toggle clamp base is 1-1/4 x 2 x 1/4". It is available with an inline mount for 10 or 15 series extrusions, or with a perpendicular mount for 10 series extrusions (diff is tapped hole locations). The perpendicular mount can be flush to the face of the extrusion, or overhang the face (requires rotating the clamp on the base). All stainless and aluminum with the exception of the 10 series t-slot nut (drill rod). Two inline available, one perpendicular. $28 each set.

The smallest 101-D base is an inline 15 series base that measures 1-3/4 x 2-1/2 x 1/4. All components are stainless steel and aluminum. All mounting screws are m6 (a bit smaller than 1/4). Two available. $30 each set, $22 w/ black steel base mounting screws (no knurled standoff).

If there is interest, I will add bases for horizontal clamps, e.g. 201-C and/or 225-D, and thicker plate options, e.g. 3/8 and 1/2". Custom base orders are also welcome, minimum 4 pieces (stock prices).

See also: Toggle Clamps
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Self Aligning T-slot Nuts

Self Aligning T-slot NutsWhen you need items mounted to T-slot extrusions to be square or parallel to the extrusion (e.g. material stops), machining them to fit the t-slot opening is not reliable. The problem is that the t-slot opening widths vary; from brand to brand, from regular to light, even from face to face on the same extrusion.

The solution is round rod T-slot nuts - 1/4" for 20 series extrusions (not shown), 5/16" with a flat for 10 and 25 series extrusions, 3/8" for 15 and 40 series extrusions. While I have only used 8020 extrusions, any similar extrusions (e.g. Faztek) should work.

Where perfectly square or parallel mounting is desired, the nuts have reamed holes to match locating pins (3/16" typ) press fit into the stop or mounting plate. Standard hole spacing is 32mm (1-1/4", free sliding and incremental bases), 1" and 25mm (incremental). Springs, typically blind holes in the nuts, insure the quick and even release of clamping pressure. Nuts with two threaded holes are standard for toggle clamp mounting bases (a flat version for t-track is also available).

Self aligning T-slot nuts are made from smooth, non marring, drill rod or stainless steel. Standard 50mm (~2") nuts, w/ tapped, reamed and spring holes, are $16ea. Toggle clamp base nuts (two tapped holes) start at $10ea. Minimum quantity: 1 for stock sizes, 4 for custom sizes/hole patterns (no extra charge if I can do them.with existing fixtures).
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ER-20 Collet Racks

ER-20 Collet RacksER-20 Collet RackThese are designed to hold 15 er-20 collets with nuts attached. They measure 6-3/4 x 4 x 1, have 3/4" holes on 34mm centers, and are made from 1/4" thick Corian and 1/4" stainless shoulder bolts. Request threaded (m4) bolts if mounting is desired. The two currently available have some chipping around the holes, so $9ea ($16 w/ tapped bolts).

The second tray is for work in progress and has 3/8" half round groves for holding bits, taps etc. It is made from 1/2" Corian, has plain steel feet (m6), and measures 6-3/4 x 3-5/8 x 7/8. One available for $18.
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Toggle Clamp T-nuts

Toggle Clamp T-nutsThe problem with toggle clamps is that you need wrenches which makes adjusting them a PITA. My T and knurled nuts make adjusting them easy. While aluminum is plenty strong in this application, the t-nuts are also available in steel and stainless steel. The rectangular stem of the T-nut does reduce spindle fore and aft adjustability. Square stems (not shown) are weaker (doesn't appear to be significant), but allow a wider range of bar travel. The m6 and 1/4-20 nuts are made from 1/2" stock and have 1/4" thick and tall stems. The m8 and 5/16-18 ones are made from 5/8" stock and have 3/8" thick stems (1/4 or 3/8" tall). $12 per T/knurl nut set (1 ea).
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