Cheap DIY camera rails mount

**jamesd256** · 20th February 2011, 05:01 AM

Hi,

I need to make some brackets for a video camera rig from aluminium on a tight budget.

Essentially we are talking about some blocks of aluminium big enough to take 2 15mm holes spaced at 60mm. They will take 15mm diameter rods which support other camera gear and accessories. The plan is to make a cut at each end from the outer edges of the pieces and tap a hole for a thumb tightening bolt to secure the rods.

I am planning to source a cheap drill stand and twist vice. I am hoping I can get enough accuracy from this type of set up.

I am happy with tolerances of up to a millimetre, so I am not expecting CNC levels of accuracy. As long as things can be tightened rigidly, small inaccuracies can be adjusted for. I can't afford to anodise, but anyway it's a bit overkill, so I'm going to go for spray finish. Any thoughts on the most cost effective spray which will offer at least some scratch resistance? Or maybe chemically dying the metal is better at hiding scratches?

Are any guidelines / links / tutorials which could be recommended for drilling largish holes in aluminium. Do I use a small pilot hole to centre the drill, and then go straight to the full 15mm? Or do I buy a set of progressively bigger drill bits and work up to 15mm? I'm planning to make quite a few of these, so purchasing guidelines on drill bits would be appreciated.

To make my lateral cuts, I was thinking buying a cheap jigsaw table to attach my cheap jigsaw to. This is just to make the cuts properly square and to be able to use a guide rail to get a straight cut.

Thanks in advance for your thoughts, and thanks for reading.

Cheers!

**neksmerj** · 20th February 2011, 01:07 PM

Welcome to the forum.

For starters, the two cross holes need to be a standard size, ie 16mm or 5/8" to suit standard size rod. I doubt there is any rod 15mm dia.

You will have a bit of a struggle drilling the holes, and will need a pilot hole through first, say 5mm dia. To drill the holes, you will need a vertical drill press (pedestal drill), a drill vice, and probably some clamps to hold the vice steady. Use kerosene as a cutting fluid.

If you don't have all the gear, I would consider farming it out to a machine shop and get 10 made or so. Unless you want to make these blocks just for the experience, having them made will probably be cheaper.

Ken

**nadroj** · 20th February 2011, 01:55 PM

I've just been pointed to a series of detailed instructional videos that look good.
Like this one on drilling:
MIT TechTV – Machine Shop 2

Suggest always use a centre punch before drilling.
Kerosene, or WD40 or similar are good cutting fluids for aluminium.
I think a vertical bandsaw would be better for the splits than a jigsaw. Better yet, a milling machine or lathe with a slitting saw on an arbour, but that means more outlay for tooling - the curse of our hobby! If you must use a jigsaw, I got a reasonable result by cutting a 10mm hole in a table top, and screwing the plate of a jigsaw underneath. The reciprocating saw blade poking up the hole, the job was easy to control on the table top. To be honest, I didn't even screw the jigsaw plate - I used a car scissor jack to clamp it in place under the table. Worked fine!

Jordan

**NCArcher** · 20th February 2011, 04:20 PM

Use progressively larger drill bits. Cut the slots with a hacksaw. Aluminium is very easy to work and you shouldn't have any problems.
When painting Aluminium you should use an etch primer before the top coat/s but you will get good results from spray cans.

**jamesd256** · 20th February 2011, 08:47 PM

Originally Posted by neksmerj

Welcome to the forum.

For starters, the two cross holes need to be a standard size, ie 16mm or 5/8" to suit standard size rod. I doubt there is any rod 15mm dia.

You will have a bit of a struggle drilling the holes, and will need a pilot hole through first, say 5mm dia. To drill the holes, you will need a vertical drill press (pedestal drill), a drill vice, and probably some clamps to hold the vice steady. Use kerosene as a cutting fluid.

If you don't have all the gear, I would consider farming it out to a machine shop and get 10 made or so. Unless you want to make these blocks just for the experience, having them made will probably be cheaper.

Ken

Thanks for the advice.

I'm in the UK, and I've managed to find a couple of suppliers of 15mm aluminium rod. Besides, the rod has to be 15mm because this is the standard for videography accessories.

I am doing it myself to gain experience, but also for the fun. I'm looking at some second hand drill stands on ebay. A drill press is out of the question right now, so I'll just have to see how good I can get it with compromised equipment.

**jamesd256** · 20th February 2011, 08:51 PM

Originally Posted by nadroj

I've just been pointed to a series of detailed instructional videos that look good.
Like this one on drilling:
MIT TechTV – Machine Shop 2

Suggest always use a centre punch before drilling.
Kerosene, or WD40 or similar are good cutting fluids for aluminium.
I think a vertical bandsaw would be better for the splits than a jigsaw. Better yet, a milling machine or lathe with a slitting saw on an arbour, but that means more outlay for tooling - the curse of our hobby! If you must use a jigsaw, I got a reasonable result by cutting a 10mm hole in a table top, and screwing the plate of a jigsaw underneath. The reciprocating saw blade poking up the hole, the job was easy to control on the table top. To be honest, I didn't even screw the jigsaw plate - I used a car scissor jack to clamp it in place under the table. Worked fine!

Jordan

Yes, I would love a CNC mill or lathe eventually, but alas not realistic at the moment.

I was looking at a cheap mounting table for the jigsaw, but I might just try your idea of making one. The one I was looking at had some nice paralel guides for aligning a fence, so I'll have to think of some way of doing that.

**jamesd256** · 20th February 2011, 08:52 PM

Originally Posted by NCArcher

Use progressively larger drill bits. Cut the slots with a hacksaw. Aluminium is very easy to work and you shouldn't have any problems.
When painting Aluminium you should use an etch primer before the top coat/s but you will get good results from spray cans.

Thanks for the advice. I'll look into etch primers.

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