Ultimate deck jig

[0001] This invention relates to the construction of deck's, specifically to the installation of decking being fastened from the top.

[0002] The installation of decking boards can be a time consuming and tedious part of construction. Decking is largely one of the most looked parts of the deck, because the decking boards cover the largest amount of surface area The decking boards are one of the first things you see when you walk on a deck.

[0003] In deck construction many different types of materials are being used to produce decking boards, from wood, composites, plastic and metal. Not only the materials used to produce the the decking a vital part of the deck's strength, just as importantly as the type of material, is the way in which you fasten the decking boards just as vital when building a deck. Spacing of the fasteners off the edges of the decking board is a crucial part of correctly fastening the decking boards to the joists or the under structure of the deck. Typically most manufactures specify the correct spacing off of the edges of the decking boards that is best suited for material type and decking board width. Most manufactures typically recommend between ¾ of an inch to 1 inch and ¼ spacing of fasteners off of the decking board edges, and always fastening the fasteners on the centerline of the joists or under structure unless otherwise instructed by the manufacturer. Thus almost eliminating the decking installers chances of missing the joist or under structure of the deck. Also another integral part of fastening the decking boards down, is the spacing between the two closest edges of the decking boards running parallel to one another. Typically the spacing between those two boards closest edges is no less than ⅛ of an inch, and usually no larger than ¼ of an inch. Which also depending on material and manufacturer of the decking boards can and typically will fluctuate on spacing between the boards closest parallel edges. Pre drilling the location of the decking board manufacturer's recommended spacing off of the edge of the decking board is almost always recommended. Depending upon what fastener the manufacturer recommends for fastening of the decking board, or what the decking board installer prefers using for strength or aesthetic purposes, he or she may have to countersink the head. Not only in most cases a countersunk head of a fastener more aesthetically appealing, the deck owner is less likely to trip on it when walking on the deck. Although many manufacturers of decking boards require pre drilling and countersinking of the fastener and or fastener head, some may not.

[0004] Resulting in cracking of the decking board specifically around the shaft of the fastener or the fastener head, depending on the hardness of the decking board material it is made out of. In some cases of non pre drilling and non countersinking the shaft or threads of the fastener may prevent full contact between decking board and joist or under structure of the deck, causing the fastener to almost push itself away from the joist or under structure. Thus not being properly fastened to the joist or under structure of the deck. Which may in turn cause tripping and ultimately compromising the strength and integrity of the deck and decking board.

[0005] So decking board manufactures and tool company's alike have long sought mean's of effectively completing all of these steps in one compact tool. Without changing his or her power drill or cordless drill. From drill bit to countersinking tool and back again. All while controlling the depth's of the drill bit, countersinking tool and the spacing of the fastener hole off of the edge of the decking board and the space between the two closest decking boards edges running parallel to one another the same on each successive decking board being installed and yet still keeping your fastener holes in the centerline of the joist or under structure of the deck and accommodating almost every manufacturers width of decking board and type of material.

[0006] In conclusion, insofar as I am aware no deck tool formerly developed provides all of these functions stated above to the user in one tool.

[0007] The invention, of a deck jig or tool that allows the user to immediately adjust the tool or deck jig with a magnetically mounted allen key on the tool as you use it. The onboard allen key is attached to the tool so that the user can quickly adjust for the thickness of the endplate,for the width of the decking board, also the depth of the drill bit and countersink and spacing of the drill bushings off of the edge of the end plate spacer or edge of the decking board edge. The onboard allen key is specifically and conveniently attached to the bottom side of the tool at all times during use to allow the user to make any or all adjustments to the tool at any time during decking board installation.

[0008] Accordingly several objects and advantages of the invention are to provide the user a tool that allows he or she to complete multiple steps by using only one tool. The Ultimate Deck Jig. Without, typically may take several different tools and more time to complete the same steps of installation of the decking boards. The Ultimate Deck Jig or tool also very accurately reproduces the same configuration of equally spaced fastener holes on the centerline of the joist or under structure of the deck while keeping the desired drill and countersinking depth the same throughout the entire process of decking board installation. Also keeping the space between the edges of the decking boards the same throughout the decking board installation. The Ultimate Deck Jig, was also designed to accommodate almost all widths and types of materials decking board manufactures produce or make. Thus the user needs only to purchase one tool to accommodate all of his or her needs for successfully installing many different types and widths of decking boards accurately every time.

[0009] FIG. 1A is a side view of the right side of the tool, constructed in accordance with the invention without drill stop tool FIG. 13A and countersinking tool FIG. 12A.

[0010] FIG. 1B is a side view of the left side of the tool without drill stop tool FIG. 13A and countersinking tool FIG. 12B.

[0011] FIG. 2A is a top view of the tool showing the two countersinking drill bushings FIG. 11A evenly spaced in the tool.

[0012] FIG. 2B is a bottom view of the tool showing the two magnets (48) holding the alien key (49) in place on the bottom side of the.

[0013] FIG. 2C is a top view as the same tool as FIG. 1A except FIG. 2C is designed for installing decking boards on a 45 degree angle.

[0014] FIG. 3A is a right side view of the tool inserted locator pin holes (56) holding end plate (41) with fastener (58) aligned to the body (46).

[0015] FIG. 3B is the same view as FIG. 3A except, this view is of the left end of the tool.

[0016] FIG. 3C is a side view of the end plate (41) the through hole (57) for the fastener(58).

[0017] FIG. 4A is a side view of the end plate (50) that is showing the two legs on the end plate for automatic centering over the joist.

[0018] FIG. 4B is a side edge view of the end plate (50)

[0019] FIG. 5A is a view of the end plate (5 1) showing only one leg on it allowing for automatic centering over the joist, by sliding the tool towards the joist with the notched out area facing the joist, until the leg on endplate (51) comes in contact with the joist.

[0020] FIG. 5B is a side edge view of the end plate (51).

[0021] FIG. 6 is a top view of the same tool as FIG. 2C only this tool is for installing decking boards on a 30 degree angle.

[0022] FIG. 7 is a top view of the same tool as FIG. 2C only this tool is for installing decking boards on a 60 degree angle.

[0023] FIG. 8A is a end view of the body (46) Shoeing the clamping slot (43) allowing for the adjustment of the width decking boards.

[0024] FIG. 8B is a end view of the extruded aluminum shape, or injection molded plastic body (46) where any end plate made for the ultimate deck jig will mount to.

[0025] FIG. 8C is a top view of body (46) showing the internal holes (56), (53) and threaded holes (60) and (52) with end plate pins (59) inserted in holes (56).

[0026] FIG. 9A is a end view of Body (46) showing the profile or shape of the aluminum extruded, or injection molded plastic body (46). also showing the radius of the finger hold area (44) without long guide pins (39) inserted in holes (56).

[0027] FIG. 9B is a end view of showing body(46) with threaded end plate fastener hole (52) used to fasten any type of end plate with fastener (47).

[0028] FIG. 9C is a top view of body (46) with end plate pins (59) and long guide pins (39) inserted in holes (56). Also showing the internal holes of body (46) including magnet holes (61) where the on board allen key (49) will be attached to magnets (48).

[0029] FIG. 10A is a top view of the small pilot hole (63) in hardened steel drill bushing (62) used to pre drill decking boards that don't need to be countersunk. The small pilot drill hole is machined into a hardened steel drill bushing (62) which guides the drill bit (68) plumb into the decking board which is then stopped at desired set depth by adjusting set screw (67) located in threaded hole machined into pilot hole drill body (65) FIG. 13A.

[0030] FIG. 10B is a side view of the small hole pilot drill bushing (62). Which shows the machined flat (77) with offset center drill hole (64) which has a conical shape to it. When the center drill hole is drilled into the drill bushing side where the two flats (77) are machined in the positive direction towards the shoulder of the drill bushing (62), off of the centerline of the side of the body (46). When tightened, the conical set screw (76) try's to bring the drill bushing (62) back on center line with the body(46) which tightens the drill bushing shoulder (62) or (38) to the top of the body (46). Keeping the drill bushing secure in the body (46) during operation.

[0031] FIG. 10C is a side view perpendicular to the machined flats (77) on small hole drill bushing (62). Machined flats (77) on drill bushing (62) or (38) is machined to fit the drill bushing slot (45) from the smaller diameter of the drill bushings (62) or (38) giving the drill bushings (62) or (38) a shoulder to be tightened to on body (46).

[0032] FIG. 10D is a side cut away view of the small hole drill bushing (62)which depicts the small hole area (63) showing a larger diameter countersunk arch machined into the drill bushing (62). When in use acts as a funnel allowing the user quicker entry of the drill bit (68) into drill bushing (62). Thus making it easier for the user to quickly and repetitiously enter and reenter the small hole (63). Making it less likely for the user to miss the small hole (63) if off center of the drill bushing (62) when the user tries to reenter drill bit (68) for another pre drilling of a decking board.

[0033] FIG. 11A is showing a top view of large hole drill bushing (38) which guides the countersinking and pilot drilling tool FIG. 12A into the center of the drill bushing (38).

[0034] FIG. 11B is a side view of drill bushing (38) which is identical to drill bushing (62) just with a larger hole (55) machined into it.

[0035] FIG. 11C is a side view of drill bushing (38) which is the same as FIG. 10C just with a larger hole (55) machined into it.

[0036] FIG. 11D is a side cutaway view of drill bushing (38) which is the same as FIG. 10D just with a larger hole (55) machined into it.

[0037] FIG. 11E is a side cutaway view of drill bushing (38A) depicting longer length bushing to guide smaller diameter pilot drill (73) to the center before making contact with decking surface

[0038] FIG. 11F is a side view of longer length drill bushing (38A)

[0039] FIG. 11G is a top view of longer length drill bushing (38A) depicting hole (55) used for countersinking tool in FIG. 15A.

[0040] FIG. 11H is a bottom view of longer length drill bushing (38A) depicting the flats (77) used for aligning drill bushing (38A) in the center in slot (45).

[0041] FIG. 12A is a side view of countersinking and pilot drilling tool, showing the the adjustable countersinking depth stop(66) and adjustable pilot hole drill area (65) by using fastener (67).

[0042] FIG. 12B is rear view of FIG. 12A depicting the three flats (69) where the chuck of a power drill or cordless drill would tighten onto. Creating three flats (69) on this area allows the chuck jaws a flat area to grip on, thus making it impossible for the countersinking and pilot drilling tool FIG. 12A or FIG. 15D to slip in the drill chuck under high torque, like a typical round drill bit would. Because the dimension at the root of the three flats (69) is smaller than the diameter that it was machined from, therefore creating three lobes or high spots of metal the chuck jaws must spin through. In order to slip in the drill chuck.

[0043] FIG. 12C is a front end view of FIG. 12A showing the countersinking shaft (71) and counter sink cutting edge (72). Also showing the cutting edge of drill bit (73) and the adjustable countersink depth stop(66).

[0044] FIG. 13A is a side view of the pilot drilling tool without countersink FIG. 13A with adjustable drill depth, by using fastener (67) to adjust depth of drill (68) and machined flat for drill chuck(69).

[0045] FIG. 13B is a rear end view showing the three drill chuck flats (69) with the shaft that the three flats were machined from (70).

[0046] FIG. 13C is a front end view of FIG. 13A showing pilot drill (68) and the fixed drill stop (65).

[0047] FIG. 14A is a side view of a pilot hole drill (73) and or (68) used for pre drilling decking boards, showing ground flat (74) which doesn't allow the drill bit (73) and or (68) to slip by tightening fastener (67) onto ground flat (74) when held in pilot hole drilling body (65).

[0048] FIG. 14B is a close to actual size rear end view of pilot hole drill bit (73) showing ground flat (74).

[0049] FIG. 14C is an enlarged end view clearly depicting the ground flat (74) on pilot hole drill bit (73).

[0050] FIG. 15A is a side view of the replaceable tip countersinking tool body (71) without the tip threaded on the body.

[0051] FIG. 15B is a cutaway side view of the replaceable countersinking tip body (83).

[0052] FIG. 15C is a side view of the replaceable countersinking tip body (83).

[0053] FIG. 15D is a side view of the replaceable tip countersinking tool assembled with pilot drill (73) shown in the tool.

• [0054] 38 countersinking tool drill bushing
• [0055] 38A. long countersinking tool drill bushing
• [0056] 39 long center guide pins
• [0057] 40 threaded holes for conical set screws
• [0058] 41 end plate
• [0059] 42 end plate fastener
• [0060] 43 clamping slit
• [0061] 44 finger gripping radius
• [0062] 45 drill bushing slot
• [0063] 46 extruded aluminum or injection molded plastic body
• [0064] 47 clamping fastener
• [0065] 48 magnets for holding allen key
• [0066] 49 allen key
• [0067] 50 place over joist end plate
• [0068] 51 slide up to joist end plate
• [0069] 52 threaded end plate fastener hole
• [0070] 53 non threaded clamping hole
• [0071] 54 threaded clamping hole
• [0072] 55 countersinking tool drill bushing hole
• [0073] 56 guide pin holes
• [0074] 57 non threaded end plate through hole
• [0075] 58 end plate fastener area
• [0076] 59 end plate locator pins
• [0077] 60 threaded conical set screw hole
• [0078] 61 magnet holes
• [0079] 62 drill bushing for pilot drill tool
• [0080] 63 arched pilot drill hole
• [0081] 64 offset center drill holes
• [0082] 65 adjustable pilot drill area
• [0083] 66 adjustable countersinking depth stop
• [0084] 67 set screw for adjusting pilot drill depth
• [0085] 68 pilot hole drill bit
• [0086] 69 machined chucking flats
• [0087] 70 larger diameter shaft chucking flats were machined from
• [0088] 71 countersinking shaft area
• [0089] 72 countersinking cutting edge area
• [0090] 73 pilot drill bit for countersinking tool
• [0091] 74 ground flat on drill bit (73)
• [0092] 75 through hole for pilot drill bit (73) and or (68)
• [0093] 76 conical set screw
• [0094] 77 drill bushing flat
• [0095] 78 machined flats for gripping with wrench, allowing for tightening of (81) to (80)
• [0096] 79 machined area behind threads (80) designed to keep mating parts (79) and (82) concentric to one another.
• [0097] 80 externally threaded area designed to screw together with (81)
• [0098] 81 internally threaded area designed to screw together with (80)
• [0099] 82 machined area designed to keep mating part (79) and (82) concentric to one another.
• [0100] 83 replaceable body, designed to be replaced when (72) looses sharp edge from wear of countersinking or desired countersinking angle (84) needs to be changed to match that of screw.
• [0101] 84 countersinking angle
• [0102] 85 machined flat area designed for fastening (66) using fastener (67) allowing for the depth of countersink to be adjusted.
  Operation

[0103] In operation one uses the ultimate deck jig by, inserting desired pre drilling tool FIG. 12A, FIG. 13A or FIG. 15D into a power drill or cordless drill chuck and tightening onto the shaft (70) specifically the three machined flats (69). After inserting the desired tool for pre drilling, the user then needs to decide what type of end plate (41), (50) or (51) and what thickness end plate the user decides to use. After the desired endplate is chosen. The user can then attach it to the body (46) FIG. 1A by using fastener (42) and tightening it by using the onboard allen key(49) FIG. 2B held by magnets (48) FIG. 2B. The user now places the tool bottom side down FIG. 1A or FIG. 1B over the decking board he or she wishes to fasten. To adjust for the width of the decking board by loosening fastener (47) FIG. 2A. After the width of the deck jig was adjusted so that the inside of the desired end plate makes contact with the outside edges of the decking board, the user can then tighten fastener (47) FIG. 2A to hold that width by clamping on fixed center guide pins (39). After the tool was set to the width of the decking board, the user can now set the drill bushings (62) FIG. 10A, (38) FIG. 11A or (38A) FIG. 11G to the desired spacing of the edge of the decking board. By using the allen key (49) FIG. 2B to loosen the conical set screw (76) and move drill bushing (62), (38) or (38A) to desired spacing and then tighten. Now that the drill bushings are set to desired spacing, the depth of the pilot drill (68) FIG. 13A, (73) FIG. 12A or (73) FIG. 15D needs to be set to desired depth. By loosening set screw (67) with alien key (49) the user can adjust the depth of of the pilot drill and then tightly tightening the set screw (67) onto the pilot drill bit holding it in place during decking board installation. For setting the depth of the countersinking and pilot drilling tool FIG. 12A is the same as setting the depth of FIG. 15D countersinking tool with replaceable tip. The only difference is with this tool FIG. 12A as opposed to FIG. 15D is the replaceable countersink tip FIG. 15C. Adjustable countersinking depth stop (66) needs to adjusted for depth of the fastener head the user decides to choose, allowing the fastener head to be countersunk flush or slightly below the decking board surface. Once the user is satisfied with the countersink depth by testing the tool in a scrap piece of material. Then the user can tightly tighten the set screw (67) with allen key (49) on shaft (71) onto machined flat area (85) FIG. 12A and FIG. 15D holding that depth of countersink throughout the rest of the decking board installation. Now the user can pre drill, countersink, space, and align for joist center all in one step all at the same time. Repeat as many times as needed.