Roy Salveson’s Edge Clamp Clamps & Vises
A Guest Project by Roy Salvesen
In need of a clamp to hold my solidwood edging in place I looked at some clamps commercially available, and really liked the design of the Bessey KF2 one handed edgeclamp:
So I decided to try to make a similar clamp made from plywood, and drew this Sketchup drawing to start with:
In the build I use 18mm (aprox 3/4″) and 9mm (aprox 3/8″) high quality birch plywood, other thicknesses can be used, but go no less than this.
I start out by printing out the templates and cutting these down to more manageable sizes:
Then I cut the plywood pieces. 2 pc 9mm plywood at aprox 160mm x160 mm” and 1 pc 18mm plywood 150mm x 100mm, 1 pc 100mm x 50mm and 1 pc 50mm x 50mm.
The 18mm piece for the cams (100mm x 50mm) should now be cut down in thickness to approximately 14.5mm (right image):
This can also be done after cutting out the cams if you are comfortable with cutting small pieces like this on the saw, but it is recommended you do it like in the first image.
I then stick the two 9mm pieces together with double sided tape:
After sticking these together I glue all templates to its mating work piece:
Parts are now cut out on the band saw, trying to stay as close to the line as possible:
After cutting all the parts it is over to the disc sander to finish shaping it close to the line:
Insides are sanded using a spindle sander:
If you don’t have a spindle sander the parts can easily be shaped by hand with a rasp/file:
Or a thin strip sander.
Drill out the center in the push pad with a forstner bit matching the size of the template.
This has to be deep enough to bury the nut on the threaded rod, plus a 1/16″ aprox:
The frame can now be glued together.
While at the drill press. Drill out 6mm holes in the cams, and also drill trough the first layer of the sandwiched 9mm ply, just deep enough to mark the lower one:
Before separating the parts make a pencil mark on the side to easily identify how to put it back together when assembled:
Now separate the two pieces and the indentation in the lower piece show where to drill the 5mm hole for the threads:
Cut the 6mm threads in the sidepice as shown here:
Now its time to glue up the clamp sides and the center filler:
Putting the 6mm bolts in the holes and start the thread to help align the two sides and shooting a couple of pins or brads to help keep the pieces in position when clamping:
2mm rubber mats are used as friction to prevent the cams from slipping on the workpiece. These also prevents damage to the surface if it is delicate.
I cut the strips using the cam width as a measurement. Using a utility knife:
The rubber pieces are roughed up with sandpaper and cleaned with denatured alcohol or similar to make a good bond for the 5 min epoxy glue:
The rubber strip is cut to length and glued up using 5 min epoxy. The strip is held in place using zip ties as the glue sets:
For the handle I start by cutting a threaded rod to aprox 150 mm and scuffing up the washer with sandpaper for good adhesion:
Thread the nuts on the rod and secure with thread lock, the washer should spin freely and have some play, and glue it to the push pad with 5 min epoxy:
Some finish sanding and rounding of the edge is done at this point before assembly takes place:
Mark and drill the 10mm hole to thread the body of the clamp:
Thread the body and use an old threaded rod with some candlelight wax on it to lubricate the wooden threads:
Run the waxed threaded rod a few times in the threads and insert the rod with the push pad:
Making the torsion springs from pianowire. Bend it 90 degrees and insert into vise along an 8 mm bolt. Wind 1 an ?? windings. 1 wound clocwise and one wound anti clockwise:
Install the torsion springs and manipulate the so that the function as they are intended:
Cut and drill dowel for handle and glue this on to the threaded rod using 5 min epoxy. I like to use these cheap bicycle rubber handles on my clamps., this is also epoxied on:
And this is the final product:
Roy has made the plans available here for free download. While you are there, check out Roy’s other plans.
Roy made a video showing the build:
To watch the latest videos from Roy, check out his YouTube channel and subscribe..