Low Profile CNC Modular Vise and Fixture Plate for Makera Z1 CNC

Please read the entire description and all instructions carefully before beginning this project. Failure to do so can cause damage to your machine, tooling, workpiece, or workholding. PDF Follow-Along Manual is also included in attachments section.

🎥Full Video of Project with Easy Follow Along Segments (with Timestamps) 🎥

This project is a custom-made low-profile modular CNC vise and fixture plate system designed specifically for the Makera Z1 CNC.

The system includes a finished fixture plate approximately 202 × 99.5 mm with a 22.5 mm staggered hole spacing pattern. The staggered layout provides more positioning options than a simple straight grid and makes it easier to fixture smaller parts, clamps, stops, and accessories in different locations across the plate.

The project also includes a matching low-profile vise designed to keep the workpiece as close to the machine bed as possible while still providing a flexible and customizable workholding setup.

The vise, as currently configured, can hold stock up to approximately 4 in. / 102 mm wide, depending on the jaw and clamping configuration being used.

One of the main goals of this design is modularity. The fixture plate can be used with the included vise, with other clamps and accessories, or with my previously released 40 mm Coin Vise.

Pressure on the movable vise jaw can be applied in two different ways:

Using the side/edge clamps from my previous project
Using the custom push bar included with this project

The custom push bar uses three M5 screws to apply controlled side pressure against the movable jaw body.

The vise, push bar, fixture plate, and other accessories can be repositioned using the fixture plate hole pattern, allowing the system to be adapted for different part sizes and machining jobs.

The project also includes a file for creating additional vise jaws, allowing you to make replacement jaws, alternate jaw styles, or your own custom soft jaws for specific parts and workholding needs.

The fixture plate itself is machined from approximately 3/8 in. / 10 mm nominal-thickness 6061 aluminum.

Project Organization

The project is divided into two main machining sections:

Part 1 – Fixture Plate
Part 2 – Low Profile Vise Components

Each Part is divided into individual Setups, and some Setups are further divided into multiple Steps, such as Setup 3A, Setup 3B, and Setup 3C.

For these instructions, a new Setup generally means that something about the physical machining setup needs to change. This may include:

Removing or repositioning the stock
Flipping the stock
Changing how the stock is located on the Z1 bed
Adding or removing a wasteboard / sacrificial board
Changing the mounting screws or clamping arrangement
Moving the stock to a different position on the machine bed
Making another physical change that affects how the workpiece is located or secured

Multiple Steps within the same Setup are used when the overall machining sequence is related, but the operation needs to be broken into separate stages.

For example, Fixture Plate Setup 3 is divided into Setup 3A, Setup 3B, and Setup 3C because several machining and workholding changes are required while completing that portion of the fixture plate.

Follow the Setups and Steps in the order shown.

Important CAM and Machine Configuration Notes

CAM Software Used for This Project

This project was set up using Makera Studio for CAM.

Makera Studio is relatively simple compared with more advanced CAM software, and its toolpath options are more limited. In particular, for this project I did not have a practical way to create the type of full-depth outside-profile cutting strategy I wanted while directly controlling radial engagement from outside the stock.

To work around this limitation, I created multiple offset toolpaths around the outside profile. Each successive offset moves closer to the finished part geometry until the final profile is reached.

This effectively reduces the amount of material being engaged by the cutter during each pass rather than attempting to remove the entire outside profile at once.

Important if Your Raw Stock Is Larger

The supplied Makera Studio toolpaths were created around the specific stock dimensions and positioning I used when making this project.

If your raw material is larger than mine, you may need to create additional outside offset passes before reaching the supplied offsets.

If your stock extends farther beyond the finished part than the stock used when these toolpaths were created, the first supplied offset may attempt to engage significantly more material than intended.

Do not assume that a larger piece of stock can simply be substituted without reviewing and modifying the outside-profile toolpaths.

In each Setup, I entered the actual stock size at that stage of the project into Makera Studio. As successive machining operations are completed, the stock dimensions change, and I updated the stock size in Makera Studio accordingly.

Keep this in mind as you move from one Setup to the next. The stock dimensions shown in a later Setup may not be the same as the original raw stock dimensions.

Double-check the stock size, stock position, origin, and toolpaths carefully for every Setup before machining.

Carefully review and simulate every toolpath before machining.

The CAM for this project was built around my particular stock size, workholding, machine setup, and machining sequence. Even if you are using the same machine, you should verify that every operation makes sense for your specific setup before running it.

Important – Endmill Installation for Full-Depth Machining

Several operations in this project machine aluminum at or near the full 10 mm+ stock thickness using a 3.175 mm endmill. This means the cutting depth can exceed three times the diameter of the cutter.

For these operations, install the endmill so the collet grips only the smooth shank, with the cutter inserted approximately to the point where the cutting edges / flutes begin.

Do not insert the cutting edges or flutes into the collet.

This provides the maximum practical support for the cutter while still leaving the full cutting length available for the deeper machining operations.

Before running any full-depth toolpath:

Make sure the collet is gripping only the smooth shank
Insert the cutter approximately to where the flutes begin
Make sure the full required cutting length remains exposed
Verify that the collet and collet nut will clear the top of the material
Confirm the cutter can safely reach the full programmed depth

Image Ref #1A – Correct 3.175 mm endmill installation showing the cutter installed in the collet

Image Ref #1B – Threading Bit showing the correct installation and exposed cutting length

Fusion 360 Users

I normally use Fusion 360 for most of my CAM work.

Fusion 360 is considerably more advanced and gives much greater control over things such as:

Radial engagement
Stepovers
Multiple-depth strategies
Lead-ins and lead-outs
Ramping
Stock-to-leave
Adaptive clearing
Entry strategies
Tool engagement
Finishing passes

It is also fairly approachable once you become familiar with the basic Manufacturing workflow, and I highly recommend taking the time to learn it if you plan on doing more advanced CNC work.

For this project, however, I made an effort to create the machining workflow in Makera Studio so that users who do not want to use Fusion 360 still have an opportunity to make the project.

If you are already comfortable using Fusion 360, I recommend setting up your own CAM in Fusion using the same general machining sequence, setup orientations, registration method, and workholding process described in these instructions.

Note About the 608 Bearing Block Machining in Video and Thumbnail Image

The 608 bearing block shown being machined after completion of the vise project, and also shown in the thumbnail image for this project, was set up using Fusion 360 CAM rather than Makera Studio.

It is shown only as a demonstration of the finished fixture plate and vise in use on another machining project.

The 608 bearing block files are not included with this project.

Very Important – Soft Limits Were Disabled

To machine the full outside profile of the fixture plate and some of the vise components, I disabled Soft Limits in the CNC configuration.

Soft limits are a software-based safety boundary that prevents the CNC from commanding movement beyond its configured working travel.

Disabling them does not give the machine additional physical travel.

If a toolpath exceeds the machine's actual physical travel, the machine may stall, lose position, collide, or cause damage.

Before running operations with soft limits disabled:

Review the entire toolpath
Simulate the operation
Verify machine movement
Check workholding clearance
Confirm the machine physically has enough travel
Stay with the machine
Be prepared to stop the job if anything does not look correct

After changing the Soft Limits setting, reset the machine for the configuration change to take effect.

Once the project is complete, re-enable Soft Limits.

Bill of Materials

The listed stock sizes are approximate. Slightly larger material is fine, but remember that the supplied toolpaths were created around the stock dimensions used for this project.

Hardware I Used
For general fixturing and mounting hardware: https://a.co/d/0fpJMYg2
For the longer M5 push-bar screws: https://a.co/d/039L6Xc9
For MDF spoil boards:https://a.co/d/0isMGzDS

Tools / Endmills Used

The following CNC cutting tools are used throughout this project:

Makera 3.175 × 12 mm For Metal
- Used for the majority of aluminum machining operations, including holes, slots, pocketing, progressive outside-profile cutting, and general part machining.
Makera M5 Threading Bit
- Used for the threaded M5 fixture holes and the threaded mounting holes used throughout the vise components.
Makera 90° Chamfering Bit – 3.175 mm Shank
- Used for the fixture plate and vise chamfering operations.
WexWe 3-Flute 6.35 mm Endmill
- Used for Fixture Plate – Setup 4 to surface the fixture plate.
- Used for Vise – Setup 7 to surface the soft jaws and machine the final jaw steps.

The individual setup instructions also identify which tools are required for each operation.

Downloading Project Files

Click Black Download Button Below Project Title. Select the CAM Tab and download individual setup files

Please note: I do not provide NC files for this project as you MUST review and generate your own G-Code. This project cannot be completed using existing G-Code files.

Part 1 – Fixture Plate

Material

Material: 6061 Aluminum
Starting Stock: approximately 8 × 4 in.
Metric Equivalent: approximately 203 × 102 mm
Nominal Thickness: 3/8 in. / 10 mm
Final Fixture Plate Size: approximately 202.1 × 99.5 mm

Fixture Plate Setup Overview

Setup 1 – Machine Bed Alignment Dowel Holes: Machine the registration dowel holes in what will become the bottom side of the fixture plate. These holes establish repeatable positioning on the Makera Z1 bed and are used to accurately register the plate during the remaining setups.
Setup 2 – Trim Right Side of Stock: Flip and re-register the stock using the dowel holes from Setup 1, then progressively trim the right side of the stock to prepare it for the final fixture plate dimensions.
Setup 3A – Mounting Recesses and Through-Holes: Machine the recessed mounting pockets and corresponding through-holes used to fasten the fixture plate directly to the Z1 bed.
Setup 3B – Final Outer Profile: Remove the top clamps, secure the fixture plate using the recessed mounting holes from Setup 3A, and progressively machine the outside profile to the final approximately 202.1 × 99.5 mm dimensions.
Setup 3C – 56 Threaded M5 Fixture Holes: Bore all 56 fixture holes to 4.2 mm, then thread them to M5 to create the staggered fixture-hole pattern.
Setup 4 – Surface Fixture Plate: Remove the wasteboard, mount the fixture plate directly to the Z1 aluminum bed, and lightly surface the top so the finished plate is referenced to the machine's actual cutting plane.
Setup 5 – Profile Chamfering and Final Finish: Chamfer the outside profile of the finished fixture plate, then lightly blend the surfaced top with a 320-grit Scotch-Brite pad for a cleaner and more uniform finish.

Fixture Plate
Setup 1: Machine Bed Alignment Dowel Holes

Purpose

Setup 1 machines the alignment dowel holes into what will become the bottom side of the fixture plate.

These holes establish the registration between the fixture plate and the Makera Z1 bed and will be used to accurately reposition the stock during the remaining machining setups. They also provide repeatable positioning of the finished fixture plate after it has been removed and reinstalled.

The stock is intentionally positioned with a small amount of material extending beyond the X− / left side of the machine bed.

Endmills / Tools Used

Makera 3.175 × 12 mm For Metal

Hardware & Fixtures / Clamps

4 × Dowel Pins
Top Clamps
Edge / Push Clamps, if available
Wide-head screws or other appropriate fixturing hardware

Prepare the Stock Edges

Before positioning the stock, inspect all of the cut edges and make sure there are no raised burrs, lips, or deformed edges extending above the stock surface.

Raised edges can prevent the stock from sitting completely flat against the Z1 bed.

Use a deburring tool, file, Scotch-Brite pad, or another suitable method to remove any raised material.

The goal is for all edges to be smooth or slightly below the main stock surface.

Stock Positioning

Insert the four dowel pins into the Z1 bed.

Image Ref #2 – Setup 1: Four dowel pin locations and initial stock positioning

Position the aluminum stock securely against the dowel pins.

When positioning the stock:

Keep the stock flush against the dowel pins
Allow approximately 0.5 mm of material to overhang the X− / left side of the Z1 bed
Clamp the stock securely
Make sure the stock sits completely flat
Make sure all workholding is clear of the toolpath

Important – Soft Limits

For this project, Soft Limits are disabled as described earlier.

After changing the Soft Limits setting, reset the machine for the configuration change to take effect.

Start Job Settings

Use the following settings when starting Fixture Plate – Setup 1:

Stock: Custom
Origin: Anchor 1 / X Offset: -15.50 mm / Y Offset: 7.00 mm
Auto Probe: Enabled / XY Probe Offsets: Use the recommended offsets
Assist Options: Auto Blow ON

After entering the Anchor 1 offsets, click Apply Settings.

Machining the Dowel Holes

The dowel holes are intentionally machined slightly undersized at first.

After the initial operation, test-fit the dowel pins.

The goal is a smooth slip fit with essentially no play.

Use small incremental adjustments to increase the hole diameter until the dowel fits correctly.

Do not oversize the holes.

Fixture Plate
Setup 2: Trim Right Side of Stock

Purpose

Setup 2 trims the right side of the aluminum stock and establishes the approximate overall stock width required for the remaining fixture plate operations.

The approximately 0.5 mm X− / left-side overhang was already established during Setup 1 by the stock position and alignment holes.

Setup 2 is machined in two stages using the same Makera Studio file.

Endmills / Tools Used

Makera 3.175 × 12 mm For Metal

Sacrificial Board Required

A wasteboard is required underneath the stock because this operation includes through-cutting.

Make sure the wasteboard is:

Flat
Securely mounted
Clean underneath the stock
Large enough to support the cutting area

Stock Position

Flip the stock along the Y-axis so the opposite face is upward.

Use two previously machined dowel holes for registration.

Image Ref #3 – Setup 2: Stock flipped along the Y-axis and positioned using two dowel pins

Secure the stock using the recommended clamp locations.

Image Ref #4 – Setup 2: Recommended clamp and mounting hardware placement

:

The stock is flipped in the correct orientation
The dowels are fully seated
The stock sits flat on the wasteboard
There are no chips underneath
All clamps and mounting hardware are clear

Do not trim the left side during Setup 2.

Setup 2 Work Origin

The CAM file uses XY0 at the center of the job.

The Y position is:

Y = 67.70 mm from Anchor 1

The X position is changed manually between the first and second trimming operations.

First Trimming Operation

HOME THE MACHINE.

Manually set:

WCS X = 0

At this position:

Machine X = -1.0 mm

Image Ref #5 – Setup 2 First Pass: WCS X set to 0 at Machine X -1.0 mm

Quick move to Anchor 1.

Manually set:

WCS Y = 0

Then Quick Move to the Work Origin.

Start Job Settings

Use the following settings for Fixture Plate – Setup 2:

Stock: Custom
Origin: Anchor 1 / X Offset: 0 mm / Y Offset: 67.70 mm
Auto Probe: Enabled / XY Probe Offsets: Relative to Path Origin X -20 mm / Y 54 mm
Assist Options: Auto Blow ON

After entering the Anchor 1 offsets, click Apply Settings.

Video Note

In the video, my Y position was not directly at Anchor 1, so I used a relative-to-current-position method.

The important points are:

X = 0 must be set correctly
The Y work origin must be 67.70 mm from Anchor 1

The XY probing offsets are selected so the probe remains on the stock.

Second Trimming Operation

Re-home the machine.

Set:

WCS X = -1.4 mm

At this position:

Machine X = -2.4 mm

Image Ref #6 – Setup 2 Second Pass: WCS X set to -1.4 mm at Machine X -2.4 mm

Re-run the same Setup 2 file.

Do not change the Setup 2 job settings.

Only the manually adjusted X work coordinate changes.

Why Setup 2 Uses Two Trimming Operations

These operations progressively trim the right side rather than attempting to remove the entire amount in a single cut.

This is consistent with the progressive-offset strategy used throughout the project.

Fixture Plate – Setup 3 Overview

Setup 3 completes the main machining of the fixture plate and is divided into three steps:

Setup 3A – Mounting Recesses and Through-Holes
Setup 3B – Final Outer Profile
Setup 3C – 56 Threaded M5 Fixture Holes

The stock remains in the same registered position throughout Setup 3, but the workholding changes after Setup 3A.

A wasteboard is required for all Setup 3 operations.

Important Note About the Video

In the video, I initially did not recess the three far-left mounting holes.

I later went back and recessed those holes as well.

I decided that recessing all of the mounting holes was the better final design because it leaves the entire fixture plate surface flush.

The final supplied project file has already been corrected and includes recessed pockets for all mounting holes.

Very Important – X+ Travel / Soft Limit Warning

Setup 3 requires extra caution because the toolpath extends approximately 1.5 mm beyond the normal X+ soft limit.

Before running Setup 3:

Confirm Soft Limits are disabled
Verify stock registration
Review and simulate the toolpaths
Verify mounting hardware clearance
Confirm physical machine travel
Stay with the machine

Fixture Plate
Setup 3A: Machine Fixture Plate Mounting Holes

Purpose

Setup 3A machines the recessed mounting holes and corresponding through-holes used to fasten the fixture plate directly to the Makera Z1 bed.

Endmills / Tools Used

Makera 3.175 × 12 mm For Metal

CAM Origin

The Setup 3 CAM origin is set to the bottom-left corner of the stock relative to Anchor 1.

Sacrificial Board Required

A wasteboard must remain underneath the fixture plate.

Workholding

During Setup 3A, keep the fixture plate secured using top clamps, in the same manner as Setup 2.

Do not remove the top clamps yet. The mounting holes machined during this step will be used to secure the plate using M5 mounting screws for Setup 3B and Setup 3C.

Image Ref #7 – Setup 3: Stock position

Start Job Settings

Use the following settings for Fixture Plate – Setup 3A:

Stock: Custom
Origin: Anchor 1 / X Offset: -15.00 mm / Y Offset: 16.70 mm
Auto Probe: DISABLED — the Z reference has not changed from the previous setup
Assist Options: Auto Blow ON

After entering the Anchor 1 offsets, click Apply Settings.

Machining Operation

Setup 3A machines:

Recessed pockets for the socket head cap screws
Corresponding M5 through-holes

The screw heads should sit below or flush with the top surface.

Reminder About the Video

The final supplied file already includes recesses for the three far-left mounting holes, even though those recesses were added later in the video.

Fixture Plate
Setup 3B: Machine Final Outer Profile

Purpose

Setup 3B brings the fixture plate to its final outside dimensions.

Final size is approximately:

202.1 × 99.5 mm

Endmills / Tools Used

Makera 3.175 × 12 mm For Metal

Prepare the Plate for Setup 3B

Before changing the workholding, vacuum all through-holes machined during Setup 3A.

Then:

Remove all top clamps
Keep the fixture plate in its registered position
Leave the wasteboard underneath
Install M5 socket head cap screws in the recessed mounting holes
Secure the plate firmly
Make sure all screw heads sit below or flush with the surface

Image Ref #8 – Setup 3B: Fixture plate secured with M5 socket head cap screws through the recessed mounting holes

Before machining, verify that:

All top clamps have been removed
The mounting screws are securely tightened
The screws are fully recessed
The dowel pins remain seated
The plate has not shifted

Progressive Outer Profile Machining

Setup 3B uses the previously described progressive offset strategy to bring the plate to its final outside dimensions.

The operation removes approximately:

1.25 mm from each side in Y
0.5 mm from each side in X

The toolpaths progressively approach the final profile to control the radial engagement of the endmill.

Image Ref #9 – Setup 3B: Progressive outside-profile offset toolpaths shown in Makera Studio

Image Ref #10 – Setup 3B: Close-up of the progressive offset toolpaths approaching the final fixture plate profile

Because the outside profile is being cut through the aluminum, the wasteboard must remain installed underneath the fixture plate.

Start Job Settings

Nothing changes from Setup 3A.

Use the following settings for Fixture Plate – Setup 3B:

Stock: Custom
Origin: Anchor 1 / X Offset: -15.00 mm / Y Offset: 16.70 mm
Auto Probe: DISABLED
Assist Options: Auto Blow ON

After entering the Anchor 1 offsets, click Apply Settings.

After Machining

Once the outer-profile operations are complete, the fixture plate should measure approximately:

202.1 × 99.5 mm

Inspect the outside edges and check all mounting screws to make sure they are still tightened correctly before proceeding to Setup 3C.

Before continuing, vacuum away all chips from the fixture plate, wasteboard, mounting holes, and surrounding machine area.

The chips produced during these full-depth profile operations are generally larger and can more easily become trapped under parts, around mounting screws, or in fixture holes.

Make sure the area is clean before moving on to Setup 3C so chips do not interfere with the workholding or cause anything to bind or get stuck.

Fixture Plate
Setup 3C: Machine the 56 Threaded M5 Fixture Holes

Purpose

Setup 3C creates the complete threaded mounting pattern used across the fixture plate.

The plate contains 56 threaded M5 holes arranged in the staggered fixture pattern.

The operation is completed in two stages:

Bore all fixture holes to 4.2 mm
Thread all 56 holes to M5

Endmills / Tools Used

Makera 3.175 × 12 mm For Metal
Makera M5 Threading Bit

Check Mounting Hardware

Before beginning Setup 3C, check the M5 mounting screws securing the fixture plate.

Make sure all of the mounting hardware is still snug and has not backed out.

Retighten any screws if needed.

Stage 1 – Bore the 4.2 mm Holes

Using the Makera 3.175 × 12 mm For Metal, bore all 56 fixture holes to:

4.2 mm

Stage 2 – Thread the Holes M5

Change to the Makera M5 Threading Bit.

Use the supplied threading operation to cut M5 threads into all 56 holes.

Start Job Settings

Nothing changes from Setup 3A / Setup 3B.

Use the following settings for Fixture Plate – Setup 3C:

Stock: Custom
Origin: Anchor 1 / X Offset: -15.00 mm / Y Offset: 16.70 mm
Auto Probe: DISABLED
Assist Options: Auto Blow ON

After entering the Anchor 1 offsets, click Apply Settings.

After Machining

Once threading is complete:

Inspect the 56 M5 threaded holes
Test several holes using M5 hardware
Remove any remaining chips or burrs
Vacuum and clean the fixture plate

Note About the Video

This is the point where I originally went back and machined the three left-most screw recesses.

The final supplied Setup 3A file already includes those recesses.

Before Setup 4:

Remove the fixture plate
Remove the wasteboard
Vacuum the machine
Clean the Z1 bed
Clean the underside of the fixture plate
Make sure all mating surfaces are chip-free

Fixture Plate
Setup 4: Surface Fixture Plate

Purpose

Setup 4 performs the final surfacing operation on the fixture plate.

For this operation, the wasteboard is removed and the fixture plate is mounted directly to the Z1 aluminum bed.

Endmills / Tools Used

WexWe 3-Flute 6.35 mm Endmill

This is the cutter I used for the surfacing operation.

The supplied project file also includes separate surfacing toolpaths for:

3.175 mm
6 mm
6.35 mm

Make sure you only export and run the surfacing toolpath that matches the diameter of the endmill you are actually using.

Remove the Wasteboard

The wasteboard is not used for Setup 4.

Clean the Z1 aluminum bed thoroughly.

Even a small chip trapped under the plate can affect the final surfaced plane.

Reinstall the Fixture Plate

Reseat the finished fixture plate directly onto the Z1 aluminum bed.

Use the previously machined 4 mm dowel alignment holes.

Make sure:

The Z1 bed is clean
The underside of the plate is clean
The dowel pins are seated
The fixture plate sits flat
The M5 mounting screws are securely tightened

Optional Shorter 4 mm Dowel Pins

Shorter 4 mm dowel pins can be useful for fixture work and may be more convenient than the longer Makera-supplied pins.

Why Surface the Plate in Its Final Installed Position?

Surfacing the plate in its final installed position references the top surface directly to the actual spindle and machine-bed relationship.

This helps compensate for small variations in the plate, bed, mounting, and spindle tram.

Surfacing Depth

Only approximately:

0.10–0.15 mm

should normally need to be removed.

Before surfacing, make sure there is enough clearance between the top of the recessed mounting screw heads and the material surface so the surfacing cutter cannot contact the screws.

Image Ref #11 – Setup 4: Measuring the clearance between the recessed mounting screw heads and the top surface of the fixture plate before surfacing

Start Job Settings

Use the following settings for Fixture Plate – Setup 4:

Stock: Custom
Origin: Anchor 1 / X Offset: -15.00 mm / Y Offset: 17.95 mm
Auto Probe: Enabled
XY Probe Relative to Work Origin: X 30 mm / Y 5 mm
Assist Options: Auto Blow ON

After entering the Anchor 1 offsets, click Apply Settings.

Fixture Plate
Setup 5: Profile Chamfering

Purpose

Setup 5 adds the final chamfer around the outside profile of the fixture plate.

This operation is separated from Setup 4 because it requires a tool change.

Endmills / Tools Used

Makera 90° Chamfering Bit – 3.175 mm Shank

Start Job Settings

Nothing changes from Setup 4.

Use the following settings for Fixture Plate – Setup 5:

Stock: Custom
Origin: Anchor 1 / X Offset: -15.00 mm / Y Offset: 17.95 mm
Auto Probe: Disabled
Assist Options: Auto Blow ON

After entering the Anchor 1 offsets, click Apply Settings.

Final Surface Finishing

Once the chamfering operation is complete, I use a 320-grit Scotch-Brite pad to lightly work the top surface of the fixture plate.

This helps remove the remaining machining marks and blends the surfaced finish into a smoother, more uniform top surface.

Work evenly across the plate and avoid concentrating too much pressure in one area.

Image Ref #12 – Setup 5: Finishing the top surface of the fixture plate with a 320-grit Scotch-Brite pad

Optional Hole Chamfering

If you have a suitable hole-chamfering tool, you can also apply a very light chamfer to the top and bottom edges of the fixture holes.

Keep this minimal so you do not unnecessarily enlarge the openings or reduce thread engagement.

After finishing:

Clean away abrasive residue
Clean the threaded holes
Inspect the outside-profile chamfer
Make sure the mounting surfaces are clean

At this point, the fixture plate is complete.

Part 2 – Low Profile Vise Components

This section covers machining the low-profile vise components from approximately 6 × 4 × 3/8 in. / 152 × 102 × 10 mm 6061 aluminum stock.

The vise project includes:

Fixed jaw body
Movable jaw body
Two replaceable soft jaws
Push bar

To avoid confusion with the earlier fixture plate setups, every setup in this section is specifically identified as Vise – Setup 1, Vise – Setup 2, and so on.

Vise Setup Overview

Vise – Setup 1 – Through-Holes, Slots, and Soft-Jaw Threading: Machine the initial through-holes and slots in the 6 × 4 in. aluminum stock, along with the threaded mounting holes used for the replaceable soft jaws.
Vise – Setup 2 – Bulk Material Removal: Reinstall the completed fixture plate, add the MDF wasteboard, and secure the vise stock using the holes and slots from Vise – Setup 1. Pocket away most of the excess aluminum.
Vise – Setup 3 – Final Profiling and Chamfers: Machine the final outside profiles using progressive full-depth offset passes, then complete the chamfering operations.
Vise – Setup 4 – Fixed Jaw Body M5 Mounting Holes: Position the completed fixed jaw body directly on the Makera CNC bed and machine the M5 mounting holes used to attach its replaceable soft jaw.
Vise – Setup 5 – Movable Jaw Body M5 Mounting Holes: Position the completed movable jaw body directly on the Makera CNC bed and machine the M5 mounting holes used to attach its replaceable soft jaw.
Vise – Setup 6 – Push Bar Side Through-Holes: Machine the side through-holes for the three M5 tensioning screws from both sides of the push bar.
Vise – Setup 7 – Final Jaw Surfacing and Jaw Steps: Reinstall the fixture plate, fully assemble the vise, surface both soft jaws together so they finish at the same height, then machine the final jaw steps.

Vise
Setup 1: Through-Holes, Slots, and Soft-Jaw Threading

Purpose

Vise – Setup 1 machines the features needed to prepare the 6 × 4 in. aluminum stock for the remaining vise operations.

This setup includes:

The required through-holes
The required slots
The threaded mounting holes used for the replaceable soft jaws

These features are machined while the stock is positioned using Anchor 1 as the reference.

The through-holes and slots machined during Vise – Setup 1 will later be used to secure the stock to the completed fixture plate for the remaining vise machining operations.

The threaded mounting holes are also completed during this stage so the fixed jaw body and movable jaw body are prepared for the replaceable soft jaws.

Endmills / Tools Used

Makera 3.175 × 12 mm For Metal
Makera M5 Threading Bit

Stock

Use approximately:

6 × 4 in.
152 × 102 mm
3/8 in. / 10 mm nominal thickness

6061 aluminum stock as listed in the BOM.

As with the fixture plate stock, inspect the aluminum before mounting it and remove any raised burrs, lips, or deformed cut edges that could prevent it from sitting flat.

Stock Positioning

Position the aluminum stock using Anchor 1 as shown in the reference image below.

Make sure the stock is:

Sitting completely flat
Properly positioned against the intended reference
Securely clamped
Free of chips or debris underneath
Positioned so all clamps and mounting hardware are clear of the machining areas

Image Ref #13 – Vise – Setup 1: 6 × 4 in. aluminum stock positioned at Anchor 1

Start Job Settings

Use the following settings when starting the Vise – Setup 1 job:

Set Stock: Anchor 1
Origin: Anchor 1 / X Offset: 0 mm / Y Offset: 0.00 mm
Auto Probe: Enabled / XY Probe Offsets: Use the recommended offsets from Path Origin
Assist Options: Auto Blow ON

After entering the Anchor 1 offsets, click Apply Settings.

Carefully verify the stock position, origin, probing location, clamps, and toolpath before starting the job.

Machining Operations

Run the supplied Vise – Setup 1 operations to machine the through-holes and slots required for mounting the stock during Vise – Setup 2.

Also complete the threaded holes used to attach the two replaceable soft jaws.

Once Vise – Setup 1 is complete, vacuum and clean the stock thoroughly before removing it from the machine.

Make sure the through-holes and slots are completely clear of chips, since they will be used as part of the workholding system in Vise – Setup 2.

Vise
Setup 2: Bulk Material Removal

Purpose

Vise – Setup 2 removes the majority of the excess aluminum surrounding the individual vise components.

The completed fixture plate is now reinstalled on the Makera Z1 and used as the workholding platform for the remaining vise machining operations.

The vise stock is secured to the fixture plate using the through-holes and slots machined during Vise – Setup 1.

Endmills / Tools Used

Makera 3.175 × 12 mm For Metal

Reinstall the Fixture Plate

Reinstall the completed fixture plate using its alignment holes and mounting hardware.

Make sure to use the two alignment dowels to accurately register the fixture plate back to its known position on the Makera Z1 bed.

Do not rely on the mounting screws alone for alignment. The mounting screws secure the fixture plate, while the two alignment dowels establish its repeatable position.

Do not install the three left-most fixture plate mounting screws at this stage. These three locations will instead be secured using the three mounting screws that pass through the fixed-jaw-body portion of the 6 × 4 in. vise stock.

Leaving these three fixture plate holes open allows the fixed-jaw-body portion of the stock to use those same mounting locations when the vise stock is installed.

Make sure:

The Z1 bed is clean
The underside of the fixture plate is clean
Both alignment dowels are properly installed and seated
The fixture plate is fully registered against the alignment dowels
The fixture plate sits completely flat
The remaining fixture plate mounting screws are securely tightened
The three left-most mounting holes remain open

Image Ref #14 – Vise – Setup 2: Completed fixture plate reinstalled with the three left-most mounting screw locations left open for the fixed-jaw portion of the vise stock

Wasteboard Required

A wasteboard is required between the completed fixture plate and the 6 × 4 in. aluminum vise stock.

A wasteboard file is included with the project and can be machined from the MDF listed in the Bill of Materials.

Place the finished wasteboard directly onto the fixture plate before installing the aluminum vise stock.

Image Ref #15 – Vise – Setup 2: MDF wasteboard positioned on top of the completed fixture plate

Make sure the wasteboard is sitting completely flat and that there are no chips or debris trapped between the wasteboard and fixture plate before installing the aluminum stock.

Stock Positioning

Position the 6 × 4 in. aluminum vise stock on the right side of the fixture plate.

Align the stock so the previously machined holes and slots line up with the available mounting locations in the fixture plate.

Use all available mounting holes and slots to secure the stock to the fixture plate. This provides the most rigid support possible for the bulk material-removal operations.

Image Ref #16 – Vise – Setup 2: 6 × 4 in. aluminum stock positioned on the right side of the fixture plate and aligned with the available mounting holes

Before tightening the stock completely, make sure:

The stock is positioned on the right side of the fixture plate
The wasteboard remains flat underneath
The machined holes and slots are correctly aligned with the fixture plate
The stock is sitting flat
There are no chips trapped between the stock, wasteboard, or fixture plate

Secure the Stock

Use the through-holes and slots created during Vise – Setup 1 to secure the stock to the fixture plate.

The three mounting screws passing through the fixed-jaw-body portion of the 6 × 4 in. stock also secure the left side of the fixture plate through the three mounting locations intentionally left open during installation.

Before machining, make sure:

All available mounting locations are being used where practical
The wasteboard is seated flat against the fixture plate
The aluminum stock is seated flat against the wasteboard
There are no chips trapped between any mating surfaces
All mounting screws are securely tightened
The three fixed-jaw-body mounting screws are properly installed
The stock cannot move or rock
All mounting hardware is clear of the toolpaths

Start Job Settings

Use the following settings when starting the Vise – Setup 2 job:

Set Stock: Anchor 1
Origin: Anchor 1 / X Offset: -15.00 mm / Y Offset: 17.95 mm
Auto Probe: Enabled / XY Probe Relative to Work Origin: X 40.00 mm / Y 35.00 mm
Assist Options: Auto Blow ON

The XY probe location is intentionally offset to avoid the machined slots and holes in the vise stock.

After entering the Anchor 1 offsets, click Apply Settings.

Carefully verify the stock position, origin, probing location, and toolpath before starting the job.

Bulk Pocketing Operations

Vise – Setup 2 removes most of the excess stock using pocketing operations.

The goal is to remove the bulk of the material surrounding the fixed jaw body, movable jaw body, soft jaws, and push bar while leaving the final outside profiles for Vise – Setup 3.

In the video, I use a 3.175 mm endmill for these pocketing operations.

This works well, but some of the larger pocketed areas can take a significant amount of time with a 3.175 mm cutter.

If you have a suitable larger-diameter endmill available, you can use it for the larger pocketing operations to reduce machining time.

I kept the 3.175 mm endmill because I did not mind the additional machining time and it kept the workflow simple.

If you choose to use a larger tool, make sure you create a toolpath that properly matches the diameter of the cutter you are actually using.

Do not run a toolpath created for a different tool diameter.

After Vise – Setup 2

Once the pocketing operations are complete, most of the excess stock surrounding the individual vise components should be removed.

The components should still remain securely supported for the final profiling operation.

Vacuum away the chips and check all mounting screws to make sure they are still tightened correctly before proceeding to Vise – Setup 3.

Vise
Setup 3: Final Part Profiling and Chamfers

Purpose

Vise – Setup 3 completes the final outside profiles of the vise components and adds their finishing chamfers.

The components remain mounted to the fixture plate through the wasteboard using the workholding established during Vise – Setup 2.

Before starting this setup, check every mounting screw and make sure it is still fully tightened. The previous bulk-material-removal operations may have caused some of the mounting hardware to loosen slightly.

Do not begin the final profiling operations until the stock is firmly secured and cannot move.

Image Ref #17 – Vise – Setup 3: Checking and tightening all vise-stock mounting screws before final profiling

Endmills / Tools Used

Makera 3.175 × 12 mm For Metal
Makera 90° Chamfering Bit – 3.175 mm Shank

Start Job Settings

Use the following settings when starting the Vise – Setup 3 job:

Set Stock: Anchor 1
Origin: Anchor 1 / X Offset: -15.00 mm / Y Offset: 17.95 mm — same as Vise – Setup 2
Auto Probe: DISABLED
Assist Options: Auto Blow ON

After entering the Anchor 1 offsets, click Apply Settings.

Carefully verify the stock position, origin, and toolpath before starting the job.

Final Profile Machining

The final profiles are machined using a strategy similar to the one used earlier for the fixture plate.

The supplied toolpaths use multiple full-depth offset passes.

Each successive offset moves closer to the final part profile.

This progressively reduces the remaining material around the components while controlling the amount of radial engagement on the cutter.

The final offset brings each component to its finished outside dimensions.

Carefully review each offset toolpath and make sure the amount of remaining stock matches the toolpath strategy before running the operation.

If your starting stock dimensions differ significantly from the stock used for this project, additional offset passes may be required.

Chamfering

After profiling, use the Makera 90° Chamfering Bit – 3.175 mm Shank for the supplied finishing chamfer operations.

These chamfers remove sharp machined edges and give the finished parts a cleaner appearance and feel.

After Vise – Setup 3

Once the final profiling and chamfering operations are complete, carefully remove the finished components from the fixture plate.

At this stage, the primary vise components should be separated and ready for their individual secondary operations.

Important – Remove the Fixture Plate Before Vise – Setups 4, 5, and 6

Before continuing to Vise – Setup 4, remove the completed fixture plate from the Makera Z1.

Vise – Setup 4, Vise – Setup 5, and Vise – Setup 6 are performed directly on the Makera CNC bed without the fixture plate installed.

After removing the fixture plate:

Vacuum the machine thoroughly
Clean the Z1 aluminum bed completely
Remove all chips and debris
Make sure the bed surface is clean before positioning the individual vise components

Even a small chip trapped underneath a part can affect its position or prevent it from sitting flat during these secondary operations.

Vise
Setup 4: Fixed Jaw Body M5 Mounting Holes

Purpose

Vise – Setup 4 machines the M5 mounting holes in the fixed jaw body used to attach its replaceable soft jaw.

This is a separate setup because the completed fixed jaw body is now positioned and machined individually.

These threaded mounting holes allow the replaceable soft jaw to be securely attached to the fixed jaw body while still allowing it to be removed and replaced later.

Important – Stock Thickness

The supplied CAM for Vise – Setup 4 assumes a finished part thickness of approximately 10.10 mm.

If your part thickness is within approximately 10.0–10.2 mm, the supplied CAM should be suitable without modification.

If your part is thicker than approximately 10.2 mm, make the necessary adjustments to the CAM before machining so the toolpaths correctly account for your actual material thickness.

Endmills / Tools Used

Makera 3.175 × 12 mm For Metal
Makera M5 Threading Bit

Part Positioning

Position the completed fixed jaw body according to the supplied Vise – Setup 4 project file, using the Anchor 1 position directly on the Makera CNC bed.

If you have one available, use a thick L-Bracket for this setup. A thick L-Bracket provides the most rigid and stable workholding for the fixed jaw body during these operations.

For my setup, I used:

1 thick L-Bracket
2 edge / push clamps

If a thick L-Bracket is not available, multiple thin L-Brackets stacked together can also be used to create a thicker and more supportive reference surface.

Image Ref #18 – Vise – Setup 4: Fixed jaw body positioned at Anchor 1 directly on the Makera CNC bed using a thick L-Bracket and two edge / push clamps

Make sure the fixed jaw body is:

Sitting completely flat on the CNC bed
Firmly seated against the L-Bracket
Securely held by the edge / push clamps
Free of chips or debris underneath
Square to the intended setup
Positioned so all workholding is clear of the machining area

Before machining, confirm that the fixed jaw body cannot shift or rock.

Start Job Settings

Use the following settings when starting the Vise – Setup 4 job:

Set Stock: Anchor 1
Origin: Anchor 1 / X Offset: 0 mm / Y Offset: 0 mm
Auto Probe: Enabled / XY Probe Relative to Path Origin: Use the recommended XY probing location
Assist Options: Auto Blow ON

After entering the Anchor 1 offsets, click Apply Settings.

Carefully verify the stock position, origin, probing location, and toolpath before starting the job.

Important – M5 Hole Position

The M5 mounting holes used to attach the replaceable soft jaw are intentionally not centered along the X-axis of the fixed jaw body.

They are designed with an X-axis offset, so do not reposition the fixed jaw body or modify the CAM in an attempt to center these holes.

The offset shown in the supplied project file is intentional and should be maintained.

Machining Operations

First, use the Makera 3.175 × 12 mm For Metal to machine the required holes in the fixed jaw body.

Then change to the Makera M5 Threading Bit and machine the corresponding M5 threads.

These threaded holes are the mounting points that the replaceable soft jaw attaches to.

After machining, test-fit the M5 hardware and make sure the screws thread in smoothly without binding.

Vise
Setup 5: Movable Jaw Body M5 Mounting Holes

Purpose

Vise – Setup 5 machines the M5 mounting holes in the movable jaw body used to attach its replaceable soft jaw.

This is a separate setup because the completed movable jaw body is now positioned and machined individually.

These threaded mounting holes allow the replaceable soft jaw to be securely attached to the movable jaw body while still allowing it to be removed and replaced later.

Important – Stock Thickness

The supplied CAM for Vise – Setup 5 assumes a finished part thickness of approximately 10.10 mm.

If your part thickness is within approximately 10.0–10.2 mm, the supplied CAM should be suitable without modification.

If your part is thicker than approximately 10.2 mm, make the necessary adjustments to the CAM before machining so the toolpaths correctly account for your actual material thickness.

Endmills / Tools Used

Makera 3.175 × 12 mm For Metal
Makera M5 Threading Bit

Part Positioning

Position the completed movable jaw body according to the supplied Vise – Setup 5 project file, using the Anchor 1 position directly on the Makera CNC bed.

If you have one available, use a thick L-Bracket for this setup. A thick L-Bracket provides the most rigid and stable workholding for the movable jaw body during these operations.

For my setup, I used:

1 thick L-Bracket
2 edge / push clamps

If a thick L-Bracket is not available, multiple thin L-Brackets stacked together can also be used to create a thicker and more supportive reference surface.

Image Ref #19 – Vise – Setup 5: Movable jaw body positioned at Anchor 1 directly on the Makera CNC bed using a thick L-Bracket and two edge / push clamps

Make sure the jaw body is:

Sitting completely flat on the CNC bed
Firmly seated against the L-Bracket
Securely held by the edge / push clamps
Free of chips or debris underneath
Square to the intended setup
Positioned so all workholding is clear of the machining area

Before machining, confirm that the jaw body cannot shift or rock.

Start Job Settings

Use the following settings when starting the Vise – Setup 5 job:

Set Stock: Anchor 1
Origin: Anchor 1 / X Offset: 0 mm / Y Offset: 0 mm
Auto Probe: Enabled / XY Probe Relative to Path Origin: Use the recommended XY probing location
Assist Options: Auto Blow ON

After entering the Anchor 1 offsets, click Apply Settings.

Carefully verify the stock position, origin, probing location, and toolpath before starting the job.

Important – M5 Hole Position

The M5 mounting holes used to attach the replaceable soft jaw are intentionally not centered along the X-axis of the movable jaw body.

They are designed with an X-axis offset, so do not reposition the movable jaw body or modify the CAM in an attempt to center these holes.

The offset shown in the supplied project file is intentional and should be maintained.

Machining Operations

First, use the Makera 3.175 × 12 mm For Metal to machine the required holes in the movable jaw body.

Then change to the Makera M5 Threading Bit and machine the corresponding M5 threads.

These threaded holes are the mounting points that the replaceable soft jaw attaches to.

After machining, test-fit the M5 hardware and make sure the screws thread in smoothly without binding.

Vise
Setup 6: Push Bar Side Through-Holes

Purpose

Vise – Setup 6 machines the side through-holes in the push bar for the three M5 tensioning screws.

The completed push bar is designed to use three captured M5 nuts, which are inserted later during assembly.

The long M5 tensioning screws pass through the side holes in the push bar and thread into these captured nuts. When tightened, the screws apply pressure against the movable jaw body.

Important – Stock Thickness

The supplied CAM for Vise – Setup 6 assumes a finished part thickness of approximately 10.10 mm.

If your part thickness is within approximately 10.0–10.2 mm, the supplied CAM should be suitable without modification.

If your part is thicker than approximately 10.2 mm, make the necessary adjustments to the CAM before machining so the toolpaths correctly account for your actual material thickness.

Endmills / Tools Used

Makera 3.175 × 12 mm For Metal

Part Positioning

Position the completed push bar according to the supplied Vise – Setup 6 project file, directly on the Makera CNC bed.

Image Ref #20 – Vise – Setup 6: Push bar positioned directly on the Makera CNC bed for side-hole machining

Make sure the push bar is:

Sitting completely flat on the CNC bed
Properly positioned against the intended reference
Securely held
Free of chips or debris underneath
Square to the intended setup
Positioned so all workholding is clear of the machining area

Before machining, confirm that the push bar cannot shift or rock.

Start Job Settings

Use the following settings when starting the Vise – Setup 6 job:

Set Stock: Anchor 1
Origin: Anchor 1 / X Offset: 0 mm / Y Offset: 0 mm
Auto Probe: Enabled / XY Probe Relative to Path Origin: Use the recommended XY probing location
Assist Options: Auto Blow ON

After entering the Anchor 1 offsets, click Apply Settings.

Carefully verify the stock position, origin, probing location, and toolpath before starting the job.

Machine Both Sides Using the Same Setup

The push bar is machined from both sides using the same Vise – Setup 6 file.

First, secure the push bar in the Vise – Setup 6 position and run the supplied machining file.

Once the first side is complete:

Remove the push bar
Flip the part along the Y-axis
Reinstall it in the same Vise – Setup 6 position
Leave all Vise – Setup 6 settings exactly the same
Re-run the same Vise – Setup 6 file

Do not change the origin, offsets, or other job settings between the first and second side.

Machining the push bar from both sides creates the required passage for the three M5 tensioning screws to pass through the push bar and reach the captured M5 nuts that will be installed later during assembly.

After Vise – Setup 6

Once both sides are complete:

Clean all chips from the through-holes
Verify that the M5 screws pass freely through the holes
Make sure the screw passages align correctly with the locations for the captured M5 nuts
Confirm that the screws can pass through without binding

At this stage, the push bar machining is complete and the three captured M5 nuts can be installed later during final assembly.

Vise
Setup 7: Final Jaw Surfacing and Jaw Steps

Purpose

Vise – Setup 7 is the final machining setup for the completed low-profile vise.

This setup is also what brings the two replaceable soft jaws to the same finished height. Before this operation, it is possible that one jaw may sit slightly higher than the other. That is not a problem, because both jaws are surfaced together during this setup so their top surfaces finish at the same height.

The replaceable soft jaws are also not intended to sit flush against the fixture plate at their bottom edge. They are designed to sit approximately 0.1 mm above the fixture plate surface.

This small clearance is intentional and provides a little margin for variation when making replacement or custom soft jaws in the future. As long as the replacement jaws sit slightly above the fixture plate surface, they can be surfaced during this setup to bring both jaws to the same final height.

Vise – Setup 7 can also be repeated whenever you make a new set of replaceable soft jaws. After installing the new jaws, repeat the surfacing and jaw-step operations as needed so the new soft jaws are brought to the same installed height and the jaw steps are machined accurately in their actual assembled position.

At this stage, the vise is fully assembled with the fixed jaw body, movable jaw body, and both replaceable soft jaws installed.

This setup performs two final machining operations:

Surface the tops of both soft jaws so they are flush with each other
Machine the final jaw steps

Machining both jaws together in the assembled vise helps ensure that the finished jaw surfaces and steps are aligned to each other in the same condition in which the vise will actually be used.

Endmills / Tools Used

WexWe 3-Flute 6.35 mm Endmill

Important – If Using a Different Endmill Diameter

The supplied Vise – Setup 7 CAM is set up around the WexWe 3-Flute 6.35 mm Endmill.

If you use an endmill with a different diameter, make sure to modify the CAM so the toolpaths correctly match the actual cutter diameter you are using.

This is especially important for the jaw-step operation.

The supplied jaw-step toolpath is created as a single straight-line cut using the 6.35 mm endmill. Because the cutter itself is 6.35 mm wide, that single pass creates the full 6.35 mm jaw opening.

If you use a smaller-diameter endmill, do not simply run the same straight-line toolpath. Instead, create a rectangle centered between the two jaws with the total opening width and depth you want, then generate a toolpath that machines that rectangle using your smaller cutter.

The finished jaw-step dimensions will then be determined by the rectangle you create:

Total jaw opening width: Equal to the width of the rectangle
Step width per jaw: 50% of the rectangle width
Step depth: 3.0 mm, unless you intentionally choose a different depth

For example, a 5 mm-wide rectangle produces:

5 mm total opening
2.5 mm step width per jaw

Reinstall the Fixture Plate

Before assembling the vise, reinstall the completed fixture plate onto the Makera Z1 bed.

Make sure to use the two alignment dowels to accurately register the fixture plate back to its known position on the machine.

Do not rely on the mounting screws alone for alignment. The mounting screws secure the fixture plate, while the two alignment dowels establish its repeatable position.

Do not install the three left-most fixture plate mounting screws. These three mounting locations are reserved for the fixed jaw assembly, which will use those holes when the vise is assembled.

Image Ref #21 – Vise – Setup 7: Fixture plate reinstalled with the three left-most mounting holes left open for the fixed jaw assembly

Before tightening the remaining fixture plate mounting screws:

Install both alignment dowels
Make sure the fixture plate is fully seated against the dowels
Confirm the fixture plate is sitting completely flat on the CNC bed
Make sure there are no chips or debris trapped underneath
Leave the three left-most mounting holes open
Tighten the remaining fixture plate mounting screws only after the plate is properly registered

Assemble and Secure the Vise

Fully assemble the vise on the completed fixture plate.

Install:

The fixed jaw body
The movable jaw body
Both replaceable soft jaws
The required mounting hardware, including the three captured M5 nuts installed into the push bar
The push bar or other clamping method being used

The fixed jaw assembly uses the three left-most fixture plate mounting holes that were intentionally left open when reinstalling the fixture plate.

When installing the fixed jaw body assembly, make sure it is perfectly aligned with the left side of the fixture plate before tightening the mounting screws.

This establishes the fixed jaw body in its intended final position and should be treated as the reference position for future vise use.

Take the time to make sure the fixed jaw body is:

Fully seated in its mounting position
Straight and square
Precisely aligned with the left edge of the fixture plate
Securely tightened so it cannot shift

Once aligned and tightened, this becomes the final installed position of the fixed jaw body for future use.

Apply pressure so that the fixed jaw body assembly and movable jaw body assembly are pressed tightly against each other with no visible gap between them.

Make sure the two jaw assemblies are fully seated against each other and held under firm clamping pressure before starting the surfacing or jaw-step operations.

Make sure all mounting screws are snug and that neither jaw assembly can move during machining.

Image Ref #22 – Vise – Setup 7: Fully assembled vise on the completed fixture plate with the fixed jaw body, movable jaw body, replaceable soft jaws, and push bar installed

Work Origin / Positioning

For Vise – Setup 7, I used the 3D probe to establish the X position by finding the center between the two assembled jaws.

With the vise fully assembled and the fixed and movable jaw assemblies pressed tightly together, use the 3D probe to locate the center between the two jaws. Use that measured center as the X work position for this setup.

For Y, use:

Y = 67.70 mm from Anchor 1

This 67.70 mm Y position is the final Y reference for the completed fixture plate and vise assembly.

From this point forward, when the completed fixture plate and vise are installed in their final registered position, the standard reference is:

X: Center between the two assembled jaws, established using the 3D probe
Y: 67.70 mm from Anchor 1

Once established, this becomes the working reference for the completed fixture plate and vise assembly going forward.

Image Ref #23 – Vise – Setup 7: Using the 3D probe to establish the X center between the two assembled jaws, with Y set to 67.70 mm from Anchor 1

Surface the Soft Jaws

The first operation lightly surfaces the tops of both replaceable soft jaws in the same machining operation.

Do not be concerned if the two jaws are not exactly the same height before this operation. The purpose of this surfacing step is to bring them to the same final installed height.

Because the jaws are surfaced while installed on the assembled vise, the final surfaces are referenced to the actual assembled workholding system rather than to the individual parts separately.

Only remove the amount of material needed to create a clean and consistent surface across both jaws.

Remember that the bottoms of the replaceable soft jaws are intentionally designed to sit approximately 0.1 mm above the fixture plate surface. They do not need to be flush with the fixture plate.

Machine the Jaw Steps

Using the WexWe 3-Flute 6.35 mm Endmill, machine the final jaw steps.

With the supplied straight-line toolpath, the two jaw steps create:

6.35 mm total opening width
3.175 mm step width per jaw
3.0 mm depth

This creates a small ledge along the inside face of each soft jaw for supporting and gripping the workpiece.

If you create a different-width rectangle as described earlier, the final opening width will match that rectangle and each jaw will receive 50% of the total rectangle width.

Machining both jaw steps in the same assembled setup helps keep the step height and geometry consistent between the fixed and movable jaws.

Why Machine the Jaws Assembled?

The final surfacing and jaw-step operations are intentionally performed with the vise fully assembled and under firm clamping pressure.

This helps make sure that:

Both soft jaws are machined at the same installed height
The top surfaces are flush with one another
The jaw assemblies are fully seated against each other
The fixed jaw body is established in its final aligned position along the left side of the fixture plate
The jaw steps are aligned
The finished geometry reflects the actual working position of the jaws
Small variations in future replacement or custom soft jaws can be corrected by surfacing them after installation

Once the surfacing and jaw-step operations are complete, the low-profile vise machining is complete.

Image Ref #24 – Completed low-profile vise assembly mounted on the finished fixture plate

Image Ref #25 – Completed low-profile vise assembly shown with jaws open

Additional / Custom Soft Jaws

A separate file is included for machining additional vise jaws.

These can be used to create:

Replacement soft jaws
Extra standard jaws
Alternate jaw styles
Custom soft jaws
Part-specific jaws for unusual shapes
Dedicated jaws for repeat machining jobs

Because the soft jaws are replaceable, they can be modified or machined directly for a particular workpiece while leaving the main fixed jaw body and movable jaw body unchanged.