Check out the 80/20 site, 80/20® Inc. - The Industrial Erector Set�they have all the joining methods you need in their catalog, you can even download software to help in your design.
I am a journeyman bicycle framebuilder. I've been using another guy's very basic framebuilding jig but want to build something better based upon this design:
Arctos Jig | Flickr - Photo Sharing!
Obviously, there's a bunch of custom machined parts there (scales and adjustments for head and seat tube adjustments are the obvious ones, but there's also the tube holding cones which I have already sourced), but I want to build this one step at a time. First, I'm not a machinist and I don't have any metalworking machinery beyond a decent drill press and a bench belt/disc sander.
I want to start with the horizontal spine and the front vertical piece. I'm planning on using a 48" length of 1545 (I'll trim it using a sliding miter saw with an Al blade) and a piece of 1530 for the vertical piece.
My question is this. How do I join the horizontal and front vertical pieces? I would assume that I can drill through the "15" side of the 1530 all the way through and use very long bolts if I tap the ends of the horizontal piece, but is there an easier or better way?
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There are real bargains there. If you need a lot of parts just email and tell them how long you think it will take you to accumulate everything, they will wait until you are done and then will ship everything together. They are very nice people; very helpful and accommodating.
Good luck on your frame building career, its an amazing human transport device you are building. [I own Assenmacher frame set 930 [built 1981]; a transcontinental touring bike.]
I would like to build a jig like this as well. Just out of curiosity, where did you find the centering cones?
I love seeing the way people jig things together. That is a nice bike jig.