Drill jig for 2020 extrusions

Easily and accurately drill holes for 2020 extrusion butt-joints.
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updated March 1, 2025

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I needed to drill holes in 2020 extrusions for a project - a bunch of butt-joints - and wanted it to be easy and repeatable.  Already had Fusion open so threw this together, iterated a few times, and walla.

  • Update: Re-uploaded with a correctly sized drill hole - 15/64 = 5.8mm (old version was 13/64 and very oops wrong) (the v5 stil is current) (note: if you need to use a bigger drill bit, just print w. more perimeters - tested this, works fine)
  • Provision for a t-nut in the perpendicular slots allows you to clamp the jig in place (which works perfectly!) - designed for a M5x16 bolt.
  • 0.1mm oversize for a nice slip fit
  • No supports required (printed on Prusa MK4S) - slice with the ‘flats’ of the hole bosses plate-side-down (i.e. the hole support structures should not be floating in the air).
  • Printed in PLA+, no issues

To use:

  1. Mark your drill point on the inside of one of the rail (center segment of the extrusion)
  2. Line up the t-nut and slide the jig onto the extrusion
  3. Using the ‘drilling’ hole as a sight, adjust the jig until you're happy it's lined up
  4. Tighten your M5 bolt/t-nut
  5. Drill away!

I did a few dozen holes using this, works like a charm.  Enjoy!

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