A drill press, hack saw, Dremel tool, and various files were used to work the metal. The bars were checked against each other for straightness and the straightest faces were used as the datum for the pins. It's hard to see, but the ends of the bars are plasti-dipped. Here are the parts for the alignment jig:
Here the jig getting dialed in. The distance between the flat surface of the countertop and the bottom of the jig is the critical measurement. Here it's dialed in to 0.0010.
0.0040 as the worst delta between standoff posts allowed, really just because that's close and it is difficult to get closer than 4 thousandths. Not bad for working on the kitchen counter.
Here are the finished jigs ready for installation onto the car. The box stuck on the side of the jig is a digital level, it may not be trustworthy though, seems like it goes in 0.15 degree increments.
I also bought 2 new tape measures with the tick marks labeled down to the 8ths to make reading the measurements easy.
Threaded Mode
