Summary

This is a remix to support more profile types. The original seems to be for V-Slot only and won't work with the profile for T-Slot.

I designed this from scratch based on the CAD drawings available from misumi (https://us.misumi-ec.com/vona2/detail/110302684350/). I tweaked it so it would also work on some other extrusion profile I have lying around as well.

There are 5mm holes on one side for drilling for the bolt, and 8.3mm holes on the other side for drilling the bolt cap head. The 5mm holes on the bottom are to help with tapping the threads in the end of the extrusion.

Make sure to insert the extrusion all the way. I have found using a small rubber mallet is useful to make sure it is bottomed out. I also sometimes need to gently tap it off afterwards. It is pretty tight for the first few uses, but does loosen up a bit.

I am using a 11/32" drill bit to widen the gap for the bolt cap head. That is slightly wider than the 8.3mm holes I designed in, but I'll leave it that way in case someone else wants to use something different. The plastic drills out easily, and the cap head holes don't require as much precision as the main 5mm holes.

After designing this, I also found https://www.thingiverse.com/thing:717903 which looks like a better option for tapping the holes into the end.