This is and end mill laser cut holder for the 10 piece grizzly end mill set seen here: http://www.grizzly.com/products/g9757
I use 3/4" x 3/4" x 1/16" aluminum for the supports or columns. This is a method that I invented. I call this self threading square tube insert method. The 4 holes on the masonite (hard board) are exactly positioned so that when they are all screwed in they "self thread" into the aluminum corners. The use of longer bolts will give a stronger hold. However for this project I used 2x 1" bolts and 2x 1/4" socket head screws.
The masonite used is 1/8". The top layer consists of 2 sheets identically cut (minus the engraving on the 2nd one). The first bottom layer is exactly the same as the top (minus the engraving). This allows for the end mills to "slide" into place and not move around. The last layer is the file that has the work "bottom" in it. It basically is only the outline and no end mill holes.
The online site I use does not allow for direct linking so here it is:
you need at least:
8x of #7981 (1/4")
8x of #5009 (1")
Get your 3/4 Aluminum Tube cut into 4x 1.2" parts. I use a metal cutting horizontal band saw. However a plain hack saw would work too. I also brush the metal with a belt sander. It adds a cool look.
Get your 1/8" material and cut 1 top layer with engraving. Cut the next 2 layers the exact same as the top but no engraving. Lastly cut the bottom layer.
Get the two top board parts and insert the 2x 1" screws and 2x 1/4" screws so that they are sticking out about 1/8". I like to place the 2x 1" screws in opposite corners then the 1/4" in the remaining corners. Rinse repreat for the rest of the top. Place the aluminum tubes under the top board so that all screws slip into the insides of all the tubes. Once aligned do 1 screw at a time on the same column until all columns are screwed in. Finally do the same for the bottom.
My Blog to read more about it here: