I’ve discovered a wall sculpture jig that has elevated the precision of my wall sculpture layouts to a new level.
I was first drawn to studying the Kreg jigs, then found the Rockler catalog online and saw that this jig would be better.
This wall sculpture jig is a Rockler product. It comes as a 4′ length of Universal T-Track, eight various length T-bolts, eight jig clamps and 8 knobs. the whole 17-piece kit is about $30.00 plus shipping.
I bought three of these kits and cut the 48″ lengths of T-track into 6″ lengths, then screwed these to the table.
In some cases I needed a special length clamp. I cut 1.25″ widths of 1/4″ aluminum to the size I needed, gave them a slight roll through the roller, drilled a hole for the 5/16″ bolts and that was all it took.
Wall Sculpture Jig – How It’s Used
I normally do my layouts on clear mylar placed over white pegboard. The mylar is for tracing the outline of the design – I first do the design right-side up, trace it, then flip everything because most of my work is done from the underside of the wall sculpture. My intent is to hide the fasteners and float the layers one above the other with spacers. The pegboard helps me line up edges and keep joints as close to 90 degrees as possible.
To the left is a general view of the table with the T-tracks and clamps. The clamps hold the pieces very, very tightly. When I drill the holes, there is no movement at all of any of the pieces.
This technique creates exact replication of the designs and perfect match-ups of the screws with the nuts.
Keep in mind this wall sculpture is flipped face down. The bottom-most pieces are now top-most. With a 3/32″ drill bit, I drill all the way through the top-most piece at the center of each junction, and then only make a divot with the drill bit in the piece below. The drilled-through hole will later be enlarged to 9/32″. The piece with the divot will have an aluminum nut welded in place, so as to be centered on the divot. Assembly will be accomplished with various lengths of 1/4″-20 screws, galvanized steel for indoors, and 304 stainless for outdoors.
To the right is a closer look at the clamps and t-tracks. One short length of t-track can hold 4 or more clamps, and with longer clamps, the reach can be extended.
You can see one circle is labeled C4-1. That means it’s the 4th largest circle and it is level 1, which means it will be on the level closest to the wall.
Wall Sculpture Jig – What I Previously Tried
It’s laughable to consider that I used to use bricks and other weights with short pieces of angle iron clamped to both legs of an angle join! It was hard to keep pieces from slipping, then lining it up again afterwards took all day. This new wall sculpture jig helps me expedite reassembly of the wall sculpture elements.
Click here for some outdoor wall sculptures I’ve made with this jig.
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