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A need exists for Ambico's machinists to precisely route a flush bolt cutout in a door with an adjustable jig that is easy to use, does not damage the door, and reduces time in the cutout process. Our solution: an adjustable steel jig which centres itself precisely via a backset guide that can be adjusted for 1 3/4" to 2 3/4 " in 1/4" increments. To get there, our team used the 5 step iterative design process and came up with a low costing, durable jig. When Ambico creates this jig, it will cost less than 50 dollars and uses recycled materials they have around their warehouse. The manufacturing process of this jig also incorporates machines that are already in Ambico's possession, to create an easy assembly process. 

A CAD model of our final design:
https://cad.onshape.com/documents/a76f5b889e0d6041acb883e7/w/c93b74e8f0524e07d4091cb1/e/161347f3fc97a219f6292d16?renderMode=0&uiState=6601b1de778a5d41f4ff24de

CAD model for prototypes:
https://cad.onshape.com/documents/323f9da910c97101955ae9ef/w/8c213120d53fd4978d23e165