With the end cap being fitted and condor tail joinery cut, the next step was to start the process of fitting the wagon vise.
First step: excavate the cavity where the screw/traveller will sit. I fit the edge guide attachment to my router base and adjusted it to my layout:
A bunch of sawdust later, there is a cavity for the traveller:
I really should move my oil rag can somewhere it won’t be a dust collector :-)
Put the end cap back on to see how it looks from the other side:
Oops! This is where re-reading the instructions and checking my layout assumptions would have helped. The end tongue and consequent mortise in the end cap is too long. I may end up having to glue a small block in the hole as there is a bolt going in that area.
Once I lined everything up again, I laid out for the bolts to hold the end cap in place. Nothing fancy, just 6” long cap screws set into a counterbore:
To get access to the other end of the bolt, I put in 1 1/2” wide, 2 1/2” deep mortises where the bolts end. Used the clamp guide and corresponding router base to make sure they lined up.
Laid out all the vise hardware to see how it looks/fits:
I can’t complete the vise install just yet. I need to install the other end cap and get the front board glued on before I can cut the grooves for the tracks.
-- Mark Kornell, Kornell Wood Design