Reply by steliart

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Posted on Clamping Cauls

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2700 posts in 2716 days

#1 posted 01-17-2011 11:53 PM

OK. Even though this thread is a one year old I will update it with my info on how I make my bow cauls.

I use 3 sizes 60cm (30”) – 90cm (36”) and 120cm (47”)

The lumber I use is kiln dried Swedish Pine with straight grain 2×2s or 2×4s
I make sure that at least the opposite edge to the crowned is made flat on your jointer.

The crowned at the ends varies according to the length of the cauls.
For the 60cm I give a 5mm crowned on both ends.
For the 90cm I give a 7mm crowned on both ends.
For the 120cm I give a 9mm crowned on both ends.

First I will get a 6mm (1/4”) MDF and cut it in size… 60×5cm (30×2”) or 90×5cm (36×2”) or 120×5cm (47×2”) and by using a bending stick or something else I will draw my curve according to which template I am doing, 5mm crowned for the 60cm, 7mm for the 90cm and 9mm for the 120cm.
Then I will cut close to the line on my band saw and sand it up to the line creating a smooth even curve.

Use this template with carpenters tape and stick it o your lumber and using a flash trim bit on your router create your smooth even curve. Then on my router table I groove (dado) in the center of straight opposite site of the crowned cauls wide enough to fit my F shape clamps. You can also do this groove with a stack dado blade on your table saw.

And there you have it… Bow cauls for any application

Oh yea. Drill a hole at one end and tie a loop so you can hang them from the wall and use some clear tape on the crowned to prevent glue up.


-- Stelios L.A. Stavrinides: - I am not so rich to buy cheap tools, but... necessity is the mother of all inventions

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