SHOE HOLE CLS JIG — VERSION 2 — PLA / PLA+
Prepared 27 October 2026

PRINT THE FIT TESTS FIRST

1. Open CLS-fit-tests-P1S-PLA.3mf in Bambu Studio.
2. Check the printer is your Bambu P1S with a 0.4 mm nozzle.
3. Choose the correct PLA or PLA+ profile for the spool you actually have,
   then slice again. The saved starting profile is Generic PLA at 220 C,
   a 55 C textured PEI bed and an 8 mm3/s flow limit.
4. Keep the models at 100% scale, in the saved orientation.
5. Print the three small samples and try several offcuts from your CLS batch.

The grooves on the outside identify the samples:
  1 groove  = 38.0 mm slot = jig file with 38p0 in its name
  2 grooves = 38.3 mm slot = jig file with 38p3 in its name
  3 grooves = 38.6 mm slot = jig file with 38p6 in its name

Choose a slot that goes on with steady hand pressure and very little play.
Do not hammer or force the timber into a tight sample. If none fits properly,
measure the timber and adjust the slot size before printing the full jig.
These samples test the width over a short length, so the full jig still needs
a gentle dry fit. Do not scale the whole model to change the slot width.

PRINT THE MATCHING JIG

Open the matching CLS-jig-v2-38pX-P1S-PLA.3mf project in Bambu Studio.
Keep the back plate flat on the bed and the open slots pointing upwards.
Use the same spool and settings as your successful fit test. Slice again
after selecting the actual spool profile. This is one colour; no AMS needed.

Saved process:
  Nozzle: 0.4 mm
  Layer height: 0.20 mm
  Wall loops: 8
  Infill: 40% gyroid
  Top and bottom: 8 layers each (1.6 mm)
  Supports: off
  Brim: off
  Outer walls: 50 mm/s; inner walls: 80 mm/s
  Flow limit: 8 mm3/s
  Scale: 100%

The slicer estimates approximately:
  All three fit tests: 40 g / 1 hour 56 minutes
  Full jig: 371 g / 14 hours 40 minutes
Estimates change with the spool profile and printer settings.

WHAT WAS STRENGTHENED

The walls increased from 6 to 10 mm and the back from 6 to 8 mm.
Curved 12 mm reinforcement supports the outside wall roots, and a 16 mm
curve reinforces the outside of the inside corner. The timber contact faces
stay flat. A 1 mm bevel at the slot mouths helps the timber slide in.
There are no thin clips, latches or separate clamping parts.

This fits the agreed layout: 38 x 63 mm CLS, 290 mm tread on top of a
200 mm riser, with a 100 mm screw centred 20 mm from the front edge.
The front and side faces share stops. Keep the pieces seated against them
while drilling and fastening. The jig slides off sideways after fastening.
The open drill area is access space, not a drill guide or a hardened bushing.

FIRST USE

Let the print cool before taking it off the bed. Check for missing layers,
separation or cracks. Remove any rough seam or burr gently without changing
the flat locating faces. Dry-fit scrap CLS and check the joint with a square.
Try drilling and screwing a scrap joint before using it for production work.
If it cracks, spreads or lets the timber rock, stop and revise the fit/design.
PLA can soften in heat, so keep the jig out of a hot van or direct heat.

WHAT HAS AND HAS NOT BEEN CHECKED

Checked: each STL is a closed, connected solid; intended timber spaces are
clear; the screwed timber has a continuous sideways removal path; a 24 mm
diameter approach space above the stated screw is clear. All four Bambu
projects sliced without warnings, with supports off, and fit on the P1S bed.

Not yet checked: physical fit, printed part strength or service life.
This is a reinforced first print, not a guarantee that it cannot snap.
No print was sent to the printer.

FILES

The .3mf files are Bambu Studio projects containing the model and settings.
The .stl files contain the model only, in millimetres and already oriented
with the back on the bed. The 38.3 mm model is shown in the web viewer.
geometry-checks.json and slicer-checks.json record the digital checks.

Slicer reference: official Bambu Studio command-line documentation
https://github.com/bambulab/BambuStudio/wiki/Command-Line-Usage
Profiles: the official presets bundled with Bambu Studio 02.08.02.61,
with the wall, infill and speed settings listed above.
