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Clamping Mitre / Miter Box for 25x11 Window Fly Screen Frames

Mitre / Miter Box with integral clamps for accurately cutting 25mm x 11mm window fly screen frames
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updated November 30, 2024

Description

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This is yet another mitre / miter box but with a unique difference!

It is designed to hold and clamp 25mm x 11mm window fly screen frames to allow for easy accurate cutting of the required 45 degree angles.

I designed it with two guided clamps that hook over and are locked onto the aluminium / aluminum stock with jackscrews. 

I personally didn't use the two jackscrews as I found it more convenient to use two 20mm long x 4.5 screws that self-tap into the central holes. Others might find the printed jackscrews useful?

The saw blade guides are 1mm wide to snugly fit standard hacksaw blades. The upright walls of the box are 10mm thick to ensure the blade is accurately guided.

I printed it with generic PLA with supports only below the two clamps which are printed at an angle as shown in the photo so the clamp guides remain smooth.

I have included the STL files to possibly make remixing a little easier.

Hope you find this useful. Let me know how it goes.

Update: After using this a few times I feel that the guide wall height needs to be increased slightly (5mm) around the slots to make commencing the cut a little easier. Not a show stopper as the cuts are perfect as is. 

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