Okay, I finally got a camera, I finally got the time, and now I can finally post my first instructable. This may be a little difficult for newest of woodworkers, but for those that passed high-school shop class with a B average this shouldn't be to hard. This is a great project for anyone who wants to upgrade their shop on a budget, or just wants to enlarge their clamp collection without making another trip to Home Depot. Teacher NotesTeachers! Did you use this instructable in your classroom? Step 1: A Note From the MakerI know that I might have more specialized equipment than some people out there, but don't let that discourage you! There is always more than one way to solve any problem out there and just because I say that you need something does not automatically make it true. There is a lot of room for improvement here. I went through 3 prototypes before I finally got this far and it is by no means perfect. Feel free to experiment and make it your own, and above all else don't be afraid to fail. Step 2: MaterialsFor this project I'm making a set of four, but I'll list the materials as if I were making one. Just multiply by the number you're making to get what you'll need. Step 3: Rip It.The best way I've found to make something is to make all of the parts you need all at once in one operation. So to start, rip the material you need for the jaws and the handles at the same time. The handles will start out 3/4 by 3/4 square, and the jaws will be 1 by 3/4. Step 4: Cutting the HandlesSet what ever machine you got to 33 degrees to cut the handle stock to shape. You can use the 1/2 inch nut as a spacer to get the thickness right. Step 5: Jaw BlanksNow cut the angle on the jaws. You can cut them any way you like. I cut mine a little long then used this jig to cut a 15 degree angle on one side. The rise and run are 2 inches by 2 3/4 for those of you that like to use a framing square, and is set up 1/2 inch or dead center in the 1inch stock. I recommend cutting the angle first then cutting the jaws to 4 inches just you have a little room for error. Step 6: Drilling Jaw AStarting with Jaw A you will need to drill two 1/2 inch holes through one side and two 1/4 inch holes through the top. Step 7: Jaw BJaw B is quite a bit different than Jaw A. It has no 1/2 inch holes drilled in it and the 1/4 inch hole in the rear is only 1/2 an inch deep. Step 8: AllthreadGet a good hack saw and cut the 1/4 inch all-thread to length. You will need a 4 1/2 inch piece and a 5 inch piece for each clamp you are making. Just set them aside for now and we'll come back to them latter when we finish up the handles. Step 9: Barrel NutsBarrel nuts are a round piece of steel drilled and tapped at a 90 degrees through it. Step 10: The Handles Chamfering the Ends.All of my handles have a chamfer cut on one end. It makes them look nice, removes the sharp edges, makes them easier to hold. Step 11: Handles ContinuedFor the handles to accept the 1/2 inch nut ferrel, it needs to be cut down to a diameter just a little larger than the hole itself so the threads will dig into the wood and help hold it in place. This is where a wood turning lathe would come in handy, but since I don't have one I'll have to make do without. Step 12: Handles, Knocking Off the Corners.The 1/2 inch nuts won't fit on the handles without taking the corners off of them. Hopefully you tested this step with a piece of scrap wood before you got to your actual handles. Step 13: Finishing Up the Handles.Screw on two 1/4 inch nuts and tighten them into each other to keep the all-thread from moving in the vise. Then round the end with a metal file so that the handle will go in smoothly. Make sure there is at least one inch of material sticking out of the vise then screw the wood handle on by hand as far as possible. Use a wrench to tighten down to the base and line up with the handle. Don't over tighten, get the nut down as far as it will go then line it up with the handle. You shouldn't have a problem with stripping the threads, the wood is pretty forgiving. Step 14: PrologueWell thats it. You have all the pieces made. Now just fit them together to make sure they all get along together, and you're finished. The only thing left to do now is sand them down, knock off the sharp corners, and add a coat of finish. Thats probably the easiest and most enjoyable step for me. Step 15: Make It BIGGER!I already did the math for you, so if you're wondering "how do I make bigger clamps than this?" here you go. |
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