How to Make an Aloris Type Tool Post Holder

Place a piece 7075 aluminum on your planer. Rip it down to 6 by 4 by 1 1/2 inches.

Deburr each face of the block after you have finished planing.

Measure and mark in 1 inch from the end of one of the 4-inch sides. Secure the block into a drill press with a bit the same size as the diameter of your tooling bar (this is usually between 3/4 inch and 1 1/2 inches).

Drill completely through the block. Remove the block from the drill press and deburr the ends of the hole.

Place the block back into the drill press. Turn the block so the tooling hole that was just made is opposite the drill bit and a 6-inch face is facing upward.

Replace the drill press bit with a 1/4-inch bit and drill three holes completely through the block. These holes should be drilled 1, 3 and 5 inches from the end of the block and inset 3/4 inch from the outer edge.

Place the block in the end mill with the three new holes opposite the cutting blade. Mill a shoulder 2 inches deep into the top side of the block. This shoulder should be a half circle with a 3-inch diameter and cover the 2- to 4-inch marks on the top of the block.

Replace the end mill blade with a 60-degree dovetail cutter blade. Cut dovetails into each side of the half circle you've just created. It is essential to use a 60-degree blade as all Aloris tool clamps use this measurement.

Place the block, tooling bar hole side up, into the drill press. Use a bit that is 1/4 inch smaller than the tooling hole. Use the drill press to cut a slot down the center of the side of the block so the tooling hole is exposed.

Remove the block from the drill press and deburr it once more.

Slide three 1/4-inch tightener screws through the three holes you drilled in the side of the block. Secure them in place with nuts.