1-1/4" Dowel Miter + Drill Guide

This was originally designed to solve the problem of owning very few power tools while building the secondary cage for my new 16" Dobsonian telescope. Rather than buying a miter saw and drill press, I was able to cut my dowels to length and center drill them with this cheap jig. 

Parts: 

2x M4 Heat Set Inserts

2x M4 Socket Head Screws

OR

2x M6 Socket Head Screws

Building:

To build this, print both models in the given orientation. The models require no supports when using PLA. Print with 3 walls and 30% infil; if you have cut through three walls, it is time to retire the tool and print a new one. 

The two holes on the miter allow you to install a pair of M4 heat set inserts with bolts, so that dowels can be held inside the miter without bending while you cut. If you don't have heat set inserts, M6 bolts should work as well, although I have not tested it. Heat set inserts are recommended, because they allow you to constantly adjust the screws without wearing out the plastic in the jig. 

The drill centering jig can be inserted into one end of the miter, and is for a 3/8" drill bit. 

Use:

This jig allows you to cut a right angle into any piece of 1-¼" dowel. The model has a 1mm kerf, however in practice this widens as you use the jig. Both ends of the jig are 5 cm from the cutting area, allowing precise measurements while cutting. 

Sometimes dowels have a flat side due to poor handling. Make sure the flat on the screw side of the miter box, to preserve concentricity.