Drysuit Neck Gasket Replacement Jig

Fusion 360 render gallery — a flat two-part jig (backing plate + split ring) that clamps a new latex neck gasket to a drysuit while the glue cures. Built parametric so every dimension is a dial.

Reverse-engineered from cgmllr100's design on Thingiverse (thanks!), which follows Kokatat's neck-gasket replacement method. v2 is snapped to the maker's source DXF — exact coordinates, not estimated. Newest version first; older versions kept.

v3thicker + rounded

Beefed up for real use. Thickness 0.5″ (12.7 mm) on both parts, and every edge rounded so nothing sharp touches the latex gasket — a generous 5 mm radius on the outer rims (the edge the gasket wraps over) and 3 mm on the finger holes and inner edges. The ring's rims are rounded before it's split, so the two halves' mating faces stay square and butt together cleanly. Same exact 241.3 mm / 165.1 mm footprint as v2.

thickness 0.5″ (12.7 mm) outer rim R5 mm inner / finger R3 mm disc_OD 241.3 mm ring_id 165.1 mm 2 half-rings

isometric render of the thicker, rounded gasket jig

top-down render of the thicker, rounded gasket jig

Left: isometric — note the rounded outer rims and the 0.5″ thickness. Right: top-down.

v2exact — from source DXF

Re-snapped to the original DXF coordinates (the maker emailed me the files). Plate: 241.3 mm (9.5″) solid disc — the maker's form is 9.5″, not the 10.5″ OEM Kokatat tool — 6 mm thick, two 40 mm finger holes centered ±50 mm from middle. Split ring: same 241.3 mm outer diameter, 165.1 mm inner hole, cut into two equal half-rings. Because the model is parametric, this was a one-line update from v1: change the parameters, geometry follows.

disc_OD 241.3 mm thickness 6 mm ring_id 165.1 mm finger_dia 40 mm 2 half-rings exact from DXF ✓

isometric render of the corrected gasket jig

top-down render of the corrected gasket jig

Left: isometric. Right: top-down. Dimensions match plate.dxf / split_ring.dxf exactly (mm units, $INSUNITS=4).

v1first build — superseded

First pass, before I had the source files. Dimensions estimated: plate sized to Kokatat's 10.5″ OEM tool (267 mm) with ring hole and finger holes scaled from the maker's product photos. Right shape, oversized — v2 corrects it to the real 9.5″ design. Plate: 267 mm disc, 6 mm thick, two 32 mm finger holes. Split ring: 267 mm OD, 160 mm inner hole, two half-rings.

disc_OD 267 mm thickness 6 mm ring_id 160 mm finger_dia 32 mm 2 half-rings fully parametric

isometric render of the gasket jig plate and split ring

top-down render showing the flat profiles

Left: isometric. Right: top-down — the flat profiles match the original DXF/SVG templates (plate with two finger holes; ring split into two halves).