Over the weekend I remade the offset post jig for a third time. This latest version is aluminum and works exceptionally well. The design is the same as previous ones with the offset profile milled on one edge and a shallow recess on the bottom that holds the blank sheet in place. I drilled a pair of holes for two small wood screws that attach the jig to the plywood base. It was an enjoyable afternoon of work.
The aluminum provides a solid, accurate surface to form the angle against. I can apply physical pressure as needed to bring the pieces into alignment. The solder won’t stick to aluminum, so there are no concerns about soldering the part to the jig.
While it’s a simple fixture, the new jig lets me produce parts with repeatable accuracy, which is my goal with any jig I make. With this experience, I see a new road of modeling opportunities opening up ahead.