|Project by ScottKaye||posted 08-08-2015 11:23 PM||1451 views||8 times favorited||5 comments|
I’ve made Cauls before, but never like these. I’ve ALWAYS struggled trying to edge clamp two board together to achieve a smooth joint and after my last glue up I knew I had to come up with a better way. The cauls are too tall to fit between my workbench and the bottom of the boards being glued up. I solved this in the past propping up the clamps with 2×4’s or whatever else I had laying around. I have come to realize that the boards I used to prop up the clamps were not uniform in thickness and some clamps where higher or lower than other clamps causing a wave effect. I ended up milling a set of 6 supports out of Fir 2×4’s that were jointed and planned to a uniform thickness. I then cut a wide dado grove that the clamp could rest in for additional support.
As for the Cauls, I used the standard construction method of hand planning the last few inches of the board, then starting a few inches closer to the center and planning the board towards its end overlapping the first cut and so on until I reached the center of the board. This of course, puts a convex or bow shape along the length of the board with the high point in the center and low points at either ends. I over the curved section with some packing tape to prevent glue adhesion. Now this is where I used a little ingenuity and routed a dado just wide enough for my Harbor Freight F Clamps to fit into. I’m sure everyone has struggle with trying to clamp cauls in place before. You really need two sets of hands to hold the cauls together while you screw the f clamp in place. The dado’s I cut into the cauls act as a third hand by holding the f clamp in loosely in place on one end while being able to attach the other clamp on the other end. It makes one person glue ups so much easier and hardly any struggle what so ever.
-- "Nothing happens until you build it"