Chevy II; The Canadian Cousin #4: New Blade Clamps

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Blog entry by shipwright posted 08-10-2015 12:36 AM 2303 reads 2 times favorited 17 comments Add to Favorites Watch
« Part 3: The Handle, an Adventure with Cocobolo and Hide Glue. Part 4 of Chevy II; The Canadian Cousin series Part 5: Repairing "Curvature of the Spine" »

Since I built my first chevalet back in 2011 I have redesigned the blade clamps at least three times, never getting one that I really liked on all levels. My constraints were lack of metal working tools and sticking to box store metal supplies. Then last winter I asked a friend who is a hobby metalworker to make me a set of clamps more like the ones that I remembered from ASFM. With his milling machine and lathe this wasn’t too hard at all.

Fast forward to last month when I decided to try to copy them for my chevy here in Canada. I still had minimal metal working tools but went to a steel supplier and got bigger stock than the box stores carry. This gave me a better chance.

To try to make a long story a little shorter, my plan was to cut a piece of 3/4” bar at 1” and then cut away a piece to leave an “L” shape. I would then fill the “L” with a separate piece of flat bar and secure with a screw to make the blade clamp.

For the shanks I would round and thread the ends of a piece of 3/8” square bar and fit one end into a tapped hole in the “L” piece.

Here are some photos that should explain all of the above.

These work just perfectly but require a lot of hand work and took almost a whole day to make. I’m too old to work that hard so …....... faced with the task of making four sets for the four new chevalets I’m making for my marquetry school I devised a “table saw” to do some of the work for me. It’s really just a mini grinder with a cut off disc to which I have added a reference surface and a sled. It works like a hot (literally) damn.
You can see my project post of the saw here.

I cut all these pieces in about a half hour.

The rest will be about the same as the hand versions but this represents most of the hard work ….... done.

Thanks for looking in.


-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fibreglass trees.

17 comments so far

View DocSavage45's profile


7649 posts in 2262 days

#1 posted 08-10-2015 12:54 AM

Your not getting older your getting tireder, and smarter. LOL! Nice save!

-- Cau Haus Designs, Thomas J. Tieffenbacher

View woodwasp's profile


33 posts in 1450 days

#2 posted 08-10-2015 01:04 AM

Love the “table saw”. Necessity the mother of invention.
Don’t worry about getting older, it is far preferable to the only alternative!

-- James -- Mooroopna Australia

View SteveGaskins's profile


621 posts in 2007 days

#3 posted 08-10-2015 01:42 AM

Very creative, Paul. I like those special jigs which are accurate, and help to save some time so I can move onto the actual build. Great job.

-- Steve, South Carolina,

View Joe Lyddon's profile

Joe Lyddon

9325 posts in 3472 days

#4 posted 08-10-2015 01:45 AM


You really developed a TOOL you can really USE!
... can you get a Patent on it? Saw & Clamps?
... Might really be worth it in the long run… :)


Thank you!

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:"

View Mark Wilson's profile

Mark Wilson

1694 posts in 483 days

#5 posted 08-10-2015 04:32 AM

I bet, Paul, that a genius like you could divine a way to build a power hack saw, with an oil dripper. A much safer instrument for cutting metal – I used one in high school metal shop. (Yeah. Four years in metal shop was completely unmarketable after graduation. Not a day in the woodshop.

So many words. I need a nap.

-- Mark

View Jim Rowe's profile

Jim Rowe

917 posts in 1732 days

#6 posted 08-10-2015 07:57 AM

Excellent solution that gives accuracy and repeatability. Great.

-- It always looks better when it's finished!

View stefang's profile


15512 posts in 2754 days

#7 posted 08-10-2015 01:19 PM

I copied your original aluminum clamps Paul and they have worked fine for me except that I didn’t do the greatest work on the square holes through the saw frame ends and there is just a little twist that I have to look out for while tightening the blade. Just the same, I can see the advantages of the steel clamps when it comes to holding power and durability, so I will probably copy what you have done here if I can get the steel stock needed, excepting the grinder jig as I only need one set. First though I have to make a new saw frame to atone for my sins on the original. Thanks much for letting us know about this latest improvement and how to best do it ourselves.

-- Mike, an American living in Norway.

View Tim's profile


3030 posts in 1381 days

#8 posted 08-10-2015 02:37 PM

That’s a great idea. I’ve been tossing around making something similar for a makeshift surface grinder but I needed some ideas. This is great.

Took me a minute to figure out why you used square stock an then filed it round, but then I saw it helps keep the blade from twisting. You could use your sled and grinder to do a bit of the rounding off too.

View shipwright's profile


7085 posts in 2218 days

#9 posted 08-10-2015 02:51 PM

I found I would over-tighten the aluminium ones and seize the steel screw. Here are some photos of a really good fix on the square holes in the saw frame. They will end up perfectly square and in perfect alignment. I think they are self explanatory.
The last shot shows the nice clamps my friend made me. They don’t work any better than my new ones but they sure are pretty.

-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fibreglass trees.

View madts's profile


1662 posts in 1760 days

#10 posted 08-10-2015 05:49 PM

Nice fix paul. Steel working is not really than woodworking.


-- Thor and Odin are still the greatest of Gods.

View CharlieK's profile


462 posts in 3213 days

#11 posted 08-10-2015 08:46 PM

Great work, Paul.

-- Adjustable Height Workbench Plans

View canadianchips's profile


2310 posts in 2417 days

#12 posted 08-10-2015 11:51 PM

YEP. I Dont know.
Do you have a video of one of chevalets in action. I think I am getting the idea of what you do with them. I would like to see one being used. Thankyou Kindly.

-- "My mission in life - make everyone smile !"

View shipwright's profile


7085 posts in 2218 days

#13 posted 08-11-2015 02:17 AM

I have several chevalet videos on my YouTube channel (paulm549) but this blog entry has a couple that will give you the general idea.

-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fibreglass trees.

View canadianchips's profile


2310 posts in 2417 days

#14 posted 08-11-2015 11:18 AM

Thankyou Paul.
I can see why people who do marquetry would like one of these.

-- "My mission in life - make everyone smile !"

View weshighfill's profile


7 posts in 1213 days

#15 posted 08-27-2015 09:15 AM

I don’t know the cost, but there are online machine shops where you send them the 3d design and they send you the parts. is just an example and one that I’ve used in the past. I was pretty pleased with the outcome.

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