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Building Dave's Bar Clamp

11K views 14 replies 3 participants last post by  Dave10 
#1 ·
Supplies and cutting

[Legebla en Esperanto]

I recently built two more of my wooden bar clamps. I decided to take photos along the way to show how they are made. These are made of 1×2 pine. Most of my bar clamps are of a very similar design. I've used them. They haven't broken and they hold wood together during glue-ups. Using a stronger wood would make the clamp… well, stronger.

N.B. I made these with basic hand tools. Using better tools will yield a more professional looking project. There are always different ways to do anything in woodworking.

For each clamp you will also need:

About 7 inches of strap steel .5 inch x 1/8 inch.

2 machine screws 1.25 inches long with 4 washers and 2 nuts

3/8 inch threaded rod about 12 inches.

2 nuts for the 3/8 inch threaded rod

2 washers sized for the threaded rod.

A piece of 1/4 inch dowel about 2 inches long.

A piece of wood 1 in x 1 in. x 4 or 5 inches long for the grip.

Wood glue

strong epoxy and/or JB Weld (other methods are OK too.)

Here we go!

Ruler Wood Office ruler Hardwood Plank


[Above] Mark out your board for pieces that are 30 in., 3.5 in., 3.5 in., 3.25 in., 3 in., 3 in., and 2 in. It's OK if the 2 in. is a wee bit over. There no real precision needed here.

Guitar accessory Wood Gas String instrument accessory Auto part


Wood Hardwood Wood stain Lumber Plywood


Wood Workbench Tool Gas Saw


[Above] Cut out the pieces. The miter box will be handy in a moment though not absolutely necessary.

Wood Musical instrument Gas Hardwood Machine


[Above] Now cut an (approximately) 45 degree angle in the 3.25 in. piece. Start in one corner and go from there. Put it aside for a while.
 

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10
#2 ·
Supplies and cutting

[Legebla en Esperanto]

I recently built two more of my wooden bar clamps. I decided to take photos along the way to show how they are made. These are made of 1×2 pine. Most of my bar clamps are of a very similar design. I've used them. They haven't broken and they hold wood together during glue-ups. Using a stronger wood would make the clamp… well, stronger.

N.B. I made these with basic hand tools. Using better tools will yield a more professional looking project. There are always different ways to do anything in woodworking.

For each clamp you will also need:

About 7 inches of strap steel .5 inch x 1/8 inch.

2 machine screws 1.25 inches long with 4 washers and 2 nuts

3/8 inch threaded rod about 12 inches.

2 nuts for the 3/8 inch threaded rod

2 washers sized for the threaded rod.

A piece of 1/4 inch dowel about 2 inches long.

A piece of wood 1 in x 1 in. x 4 or 5 inches long for the grip.

Wood glue

strong epoxy and/or JB Weld (other methods are OK too.)

Here we go!

Ruler Wood Office ruler Hardwood Plank


[Above] Mark out your board for pieces that are 30 in., 3.5 in., 3.5 in., 3.25 in., 3 in., 3 in., and 2 in. It's OK if the 2 in. is a wee bit over. There no real precision needed here.

Guitar accessory Wood Gas String instrument accessory Auto part


Wood Hardwood Wood stain Lumber Plywood


Wood Workbench Tool Gas Saw


[Above] Cut out the pieces. The miter box will be handy in a moment though not absolutely necessary.

Wood Musical instrument Gas Hardwood Machine


[Above] Now cut an (approximately) 45 degree angle in the 3.25 in. piece. Start in one corner and go from there. Put it aside for a while.
So far, I'm following…
(-:
 

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#3 ·
Supplies and cutting

[Legebla en Esperanto]

I recently built two more of my wooden bar clamps. I decided to take photos along the way to show how they are made. These are made of 1×2 pine. Most of my bar clamps are of a very similar design. I've used them. They haven't broken and they hold wood together during glue-ups. Using a stronger wood would make the clamp… well, stronger.

N.B. I made these with basic hand tools. Using better tools will yield a more professional looking project. There are always different ways to do anything in woodworking.

For each clamp you will also need:

About 7 inches of strap steel .5 inch x 1/8 inch.

2 machine screws 1.25 inches long with 4 washers and 2 nuts

3/8 inch threaded rod about 12 inches.

2 nuts for the 3/8 inch threaded rod

2 washers sized for the threaded rod.

A piece of 1/4 inch dowel about 2 inches long.

A piece of wood 1 in x 1 in. x 4 or 5 inches long for the grip.

Wood glue

strong epoxy and/or JB Weld (other methods are OK too.)

Here we go!

Ruler Wood Office ruler Hardwood Plank


[Above] Mark out your board for pieces that are 30 in., 3.5 in., 3.5 in., 3.25 in., 3 in., 3 in., and 2 in. It's OK if the 2 in. is a wee bit over. There no real precision needed here.

Guitar accessory Wood Gas String instrument accessory Auto part


Wood Hardwood Wood stain Lumber Plywood


Wood Workbench Tool Gas Saw


[Above] Cut out the pieces. The miter box will be handy in a moment though not absolutely necessary.

Wood Musical instrument Gas Hardwood Machine


[Above] Now cut an (approximately) 45 degree angle in the 3.25 in. piece. Start in one corner and go from there. Put it aside for a while.
So far, I m following…
(-:

- CFrye
I'll explain any fuzzy points. Sometimes I'm not the epitome of clarity.
 

Attachments

#4 ·
The fixed head

[Legebla en Esperanto]

Hand Tape measure Ruler Wood Office ruler


Wood Finger Font Hardwood Plant


Stonemason's hammer Hand tool Wood Axe Tool


[Above] Take the 2 inch piece and measure 1 inch from one end. That end is henceforth the bottom. Mark the center between the sides and put a dimple in that spot. I used a convenient nail here.

Plumbing valve Motor vehicle Wood Engineering Gas


Wood Gas Shear Saw Machine


[Above] Now, using a 5/8 in. bit (or better, one just big enough for the nut,) drill a hole just deep enough for the 3/8 in. nut. You can see my hole is a little large.

Drill Pneumatic tool Wood Handheld power drill Tool


[Above] In the center of the shallow hole you just drilled, now drill a 3/8 in. through hole. The threaded rod will pass through this eventually.

Wood Gas Flooring Hardwood Wood stain


[Above] Now glue the nut in the hole using the epoxy. Try not to get the epoxy in the threads of the nut. It's just easier that way.

Wood Wood stain Hardwood Flooring Plank


Wood Fluid Hardwood Gas Wood stain


[Above] Take the two 3.5 inch pieces and coat one side of each with glue. Glue them to one end of the 30 in. bar with the 2 inch piece between them. as shown. Clamp it and clean up the glue squeeze out.
 

Attachments

#5 ·
The fixed head

[Legebla en Esperanto]

Hand Tape measure Ruler Wood Office ruler


Wood Finger Font Hardwood Plant


Stonemason's hammer Hand tool Wood Axe Tool


[Above] Take the 2 inch piece and measure 1 inch from one end. That end is henceforth the bottom. Mark the center between the sides and put a dimple in that spot. I used a convenient nail here.

Plumbing valve Motor vehicle Wood Engineering Gas


Wood Gas Shear Saw Machine


[Above] Now, using a 5/8 in. bit (or better, one just big enough for the nut,) drill a hole just deep enough for the 3/8 in. nut. You can see my hole is a little large.

Drill Pneumatic tool Wood Handheld power drill Tool


[Above] In the center of the shallow hole you just drilled, now drill a 3/8 in. through hole. The threaded rod will pass through this eventually.

Wood Gas Flooring Hardwood Wood stain


[Above] Now glue the nut in the hole using the epoxy. Try not to get the epoxy in the threads of the nut. It's just easier that way.

Wood Wood stain Hardwood Flooring Plank


Wood Fluid Hardwood Gas Wood stain


[Above] Take the two 3.5 inch pieces and coat one side of each with glue. Glue them to one end of the 30 in. bar with the 2 inch piece between them. as shown. Clamp it and clean up the glue squeeze out.
I don't know why I've never considered using spade bits with my eggbeater/breast drill. What advantage is there to the washer on a string compared to just the washer?
 

Attachments

#7 ·
The Jaw

[Legebla en Esperanto]

Hand tool Wood Metalworking hand tool Saw Tool


[Above] Now take one of the 3 inch pieces and put it on the bar in front of the clamp head that you recently glued onto the bar. Mark the height of one of the side members of the head on the 3 inch piece. N.B. in this position the area above the head is going to be the fingers.

Brown Wood Rectangle Wood stain Flooring


[Above] Using the other 3 inch piece, place it in the 'finger' area of the one you just marked. Center it from side to side and mark where it sits.

Drill Drill presses Saw Drilling Wood


Wood Wood stain Hardwood Gas Machine


Hand tool Wood Tool Metalworking hand tool Garden tool


Wood Gas Saw Hardwood Composite material


[Above] Clamp the two 3 inch pieces together and 'somehow' clear out the area between the 'fingers'. I used a drill, saw, chisel, and rasp. The idea is to allow both pieces to freely move on the bar..

Wood Hand tool Wood stain Hardwood Burin


Wood Flooring Floor Wood stain Hardwood


Wood Rectangle Wood stain Plank Hardwood


[Above] Put the threaded rod through the nut just so that it protrudes. Put one of those 'finger' pieces (we'll call then jaws now) against the rod and tap it with a hammer to make a dent.

Wood Gas Machine Composite material Hardwood


Wood Amber Rectangle Font Metal


[Above] Clamp the jaw halves together, making sure the fingers match if they aren't absolutely perfect. Using the dent/mark in the face of the one jaw part, drill a 3/8 inch hole all the way through ONE JAW PART, but just a tiny bit into the other one.

Wood Rectangle Gas Hardwood Metal


[Above] Now using a 7/8 inch bit, drill a well in the half with the through hole and a shallower well in the other half, but drill completely through that one.

Wood Wood stain Hardwood Tool Composite material


Wood Gas Tool Machine Machine tool


Wood Gas Machine Hardwood Cylinder


[Above] By now the glue on the head is dry and you can cut off the extra protrusion from the 2 inch piece. Then round over the back of the head. I used a rasp.
 

Attachments

#8 ·
The Bar

[Legebla en Esperanto]

Wood Ruler Wood stain Hardwood Track


Wood Rectangle Flooring Hardwood Wood stain


[Above] Now turn the bar over to expose the bottom side. Put both jaw pieces on the bar up against the head. Measure in 2 inch increments from the jaw pieces down the length of the bar. In reality one in increments is better, but it's double the work too. Using the rat tail rasp cut half circle stops into the bar. N.B. More can be easily added after the clamp is finished. Don't go all the way to the far end.

Wood Table Tool Gas Cooking


Saw Wood Vise Stonemason's hammer Tool


Wood Table Flooring Wood stain Hardwood


[Above] Round over the far end of the clamp bar. Drill a centered 1/4 inch hole about 3/4 inch from the end. Now is a good time to sand the clamp bar.
 

Attachments

#9 ·
Finishing the jaw

[Legebla en Esperanto]

Wood Wood stain Plank Hardwood Flooring


Wood Hardwood Flooring Wood stain Mallet


Wood Gas Composite material Machine Hardwood


[Above] And here's me forgetting to photograph steps, but it's OK. Advance the threaded rod a few inches. Put the jaw half with the through-hole on the bar and with the rod through it. Put a washer on the rod and into the well you drilled. Glue the nut on the end of the threaded rod. Now you should have what is shwn in the top photo. 2nd photo: put the other washer in the well of he other jaw half. Apply wood glue to the inner surface of the jaw. 3rd photo: clamp the two halves together. You could put a few of those pesky plastic cards between the bar and the 'fingers' to keep glue off of them. You might also want to rotate the rod a few times until the wood glue sets up in case it squished inwards. The washers keep the nut from digging into the wood of the jaw. So far I haven't had problems with my clamps regarding this.
 

Attachments

#10 ·
Finishing the jaw

[Legebla en Esperanto]

Wood Wood stain Plank Hardwood Flooring


Wood Hardwood Flooring Wood stain Mallet


Wood Gas Composite material Machine Hardwood


[Above] And here's me forgetting to photograph steps, but it's OK. Advance the threaded rod a few inches. Put the jaw half with the through-hole on the bar and with the rod through it. Put a washer on the rod and into the well you drilled. Glue the nut on the end of the threaded rod. Now you should have what is shwn in the top photo. 2nd photo: put the other washer in the well of he other jaw half. Apply wood glue to the inner surface of the jaw. 3rd photo: clamp the two halves together. You could put a few of those pesky plastic cards between the bar and the 'fingers' to keep glue off of them. You might also want to rotate the rod a few times until the wood glue sets up in case it squished inwards. The washers keep the nut from digging into the wood of the jaw. So far I haven't had problems with my clamps regarding this.
I see how you did it now. Thanks.
 

Attachments

#14 ·
Movable stop

[Legebla en Esperanto]

Wood Gas Hardwood Machine Metal


[Above] Cut the piece of flat steel into two lengths of 3.25 in. Use a file to blunt the edges and round the corners a bit.

Brown Wood Flooring Floor Table


Wood Hardwood Wood stain Tool Machine


[Above] mark a point about 3/8 in. in from each end, centering it on the steel. Drill a 1/4 in. hole at these locations. You will want to use a center punch to give the drill bit a place to catch. The hole is easier to drill if you start with an 1/8 in. pilot hole, then go to the 1/4 in. bit. File any burs.

Wood Drilling Drill presses Milling Gas


Wood Wood stain Gas Hardwood Plank


Wood Tool Gas Hardwood Metal


[Above] Take the 3.25 in. piece of wood, the one you sawed the angle from and drill a hole 1 in. up from the bottom and 1 in. in from the flat end. ith the bolts, nuts, and washers you can assemble the movable stop as shown.

Wood Tool Gas Hand tool Machine


Wood Gas Hardwood Machine Automotive tire


[Above] You need to keep the nuts from loosening on the movable head. Epoxy or a thread locker will work, but I used the center punch to munge up the thread on the end of the screw. Now the stop gets slid onto the bar.
 

Attachments

#15 ·
Finishing up

[Legebla ankaĹ­ en Esperanto]

Wood Tool Gas Engineering Hardwood


[Above] After the movable stop is on the bar, insert a piece of 1/4 in. dowel into the hole at the end of the bar. This keeps the head from sliding off. The dowel can be glued in, but if it is snug, you may want to leave it be. If left removable, the possibility is open to join two clamps together to make a longer one.

Wood Tool Saw Drill Handheld power drill


Wood Flooring Floor Rectangle Gas


Wood Rectangle Wood stain Flooring Plank


[Above] Take the 1 in. x1 in. x 4 in. piece of wood and drill a 3/8 in. hole down the center about 3 in. deep. Using epoxy, glue it to the end of the threaded rod. After that sets up, your clamp is done. I finished mine with boiled linseed oil.

See the finished project page here [link]
 

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