If you’ve ever used a plunge saw with a track, you know how useful they can be for making accurate, straight cuts. However, one of the downsides of using a track is that it can sometimes be difficult to keep it securely in place. That’s where track clamps come in. These simple but effective clamps are designed to hold the track firmly in place, ensuring that your cuts are precise and consistent.
While you can buy track clamps from various manufacturers, they can often be expensive. Luckily, making your own track clamps is an easy and cost-effective solution. With just a few basic materials and some simple tools, you can create custom track clamps that are tailored to your specific needs.
To make plunge saw track clamps, you’ll need a few key components. The first is a piece of aluminum extrusion, which will serve as the main body of the clamp. This can typically be found at your local hardware store or online. You’ll also need some bolts and nuts to hold the clamp together and attach it to your plunge saw track.
Step-by-Step Guide to Making Plunge Saw Track Clamps
Materials needed:
- 2-inch by 4-inch wood beam
- Ratchet straps
- Bolts, nuts, and washers
- Drill and drill bits
- Measuring tape
Step 1: Measure and cut the wood beam
Using a measuring tape, measure the length needed for the clamps on your plunge saw track. Mark the measurement on the wood beam and use a saw to cut two pieces of the beam to that length.
Step 2: Drill holes in the wood beam
Drill two holes in each wood beam piece, one on each end. The holes should be big enough to fit the bolts you have chosen.
Step 3: Attach the ratchet straps
Slide one end of a ratchet strap through the hole on one side of the wood beam. Pull the strap through until the ratchet mechanism is close to the beam. Fold the strap back on itself and feed it through the other hole, coming out on the opposite side of the beam. The ratchet mechanism should be on the outside of the wood beam. Repeat this process for the other ratchet strap and wood beam piece.
Step 4: Attach the bolts
Place a washer on one end of a bolt, then insert the bolt through the hole in the wood beam. Add another washer and then tighten a nut onto the bolt. Repeat this process for the other hole on the same side of the wood beam. Ensure the bolt is securely fastened and the clamps are held tightly together.
Step 5: Test the clamps
Slide the clamps onto the plunge saw track, positioning them where you need them to hold the track securely. Pull the ratchet straps as tight as possible and secure them in place by tightening the ratchet mechanisms. The clamps should now firmly hold the plunge saw track in place.
Note: Ensure that the clamps are securely fastened and the ratchet straps are tight enough to hold the plunge saw track during use. Test the stability and adjust if necessary before operating the plunge saw.
Tools and Materials Required for Making Plunge Saw Track Clamps
Before you start making plunge saw track clamps, it is important to gather all the necessary tools and materials. Here is a list of what you will need:
| Tools | Materials |
| Saw | Aluminum extrusions |
| Drill | T-track stops |
| Screwdriver | Bolts and nuts |
| Clamps | Washers |
| Measuring tape | Wood screws |
| Square | Adhesive |
| Marker | Ruler |
These tools and materials will help you create sturdy and reliable plunge saw track clamps. Make sure to have them all on hand before you begin the process. It is also a good idea to have some basic woodworking skills and safety equipment like gloves and goggles.
Benefits of Using Plunge Saw Track Clamps
Plunge saw track clamps are essential tools for any woodworker or DIY enthusiast. They offer a wide range of benefits that can significantly improve your cutting accuracy and overall efficiency. Here are some of the key advantages of using plunge saw track clamps:
- Enhanced Stability: Plunge saw track clamps securely hold the track in place, providing stability and preventing any movement during the cutting process. This ensures accurate and precise cuts, even when working with large and heavy materials.
- Increased Safety: By firmly holding the track in place, plunge saw track clamps help reduce the risk of accidents and injuries. The stability they provide minimizes the chances of the track slipping or shifting while cutting, promoting a safe work environment.
- Improved Control: With plunge saw track clamps, you have better control over the saw and track alignment. This allows you to make straight and consistent cuts with ease, resulting in professional-looking finished products.
- Versatility: Plunge saw track clamps can be used with a variety of plunge saws and different track systems. This versatility allows woodworkers to work with different types of saws and adapt to various project requirements.
- Time and Effort Savings: By holding the track securely in place, plunge saw track clamps eliminate the need to use excess force to keep the track steady during cutting. This not only reduces fatigue but also speeds up the cutting process, saving you time and effort.
- Portability: Plunge saw track clamps are lightweight and easy to transport, making them ideal for both workshop and on-site use. They can be quickly set up and used with minimal effort, allowing you to work efficiently wherever your projects take you.
Overall, plunge saw track clamps are indispensable accessories that offer numerous benefits for woodworkers. From improved stability and control to increased safety and time savings, these clamps are essential tools for achieving accurate and professional-looking cuts.
Tips and Tricks for Making Plunge Saw Track Clamps
Plunge saw track clamps are essential tools for woodworking projects that require precise and controlled cuts. These clamps help secure the track in place, ensuring that the saw can glide smoothly along the desired cutting line. Here are some tips and tricks to consider when making your own plunge saw track clamps:
1. Choose the Right Material
When making plunge saw track clamps, it’s important to select a sturdy and durable material that can withstand the pressure and tension applied during cutting. Materials like aluminum or steel are often preferred for their strength and longevity. Consider the thickness and width of the material to ensure proper stability.
2. Measure and Cut Accurately
Precision is key when making plunge saw track clamps. Measure the length of your track carefully and cut the material to match the exact dimensions. Using a miter saw or a table saw with a fine-toothed blade can help achieve clean and accurate cuts.
3. Drill Bolt Holes
To attach the clamp to the track, drill bolt holes through the material. Measure and mark the hole locations using a center punch for accuracy. Use a drill bit that matches the diameter of the bolts you plan to use. Make sure the holes are aligned properly to ensure a snug and secure fit.
4. Add Rubber Grip Pads
To enhance the clamping capability of your plunge saw track clamps, consider adding rubber grip pads to the surface that comes into contact with the track. These pads will help prevent the clamp from slipping or shifting during use, ensuring a stable and reliable cutting experience.
5. Sand and Smooth Edges
After cutting and drilling, sand down any rough or sharp edges on the clamp to prevent accidental injuries or damage to the track or saw. Use sandpaper or a file to smoothen the edges, ensuring a clean and professional finish.
6. Test and Adjust
Before fully relying on your homemade plunge saw track clamps, it’s essential to test them out and make any necessary adjustments. Practice making cuts with the clamps in place to ensure that they provide the desired stability and control. If any issues arise, make necessary modifications to improve their performance.
- Always prioritize safety when using plunge saw track clamps. Wear appropriate safety gear such as goggles and gloves to protect yourself from potential hazards.
- Regularly inspect your clamps for wear and tear. Replace any damaged or worn-out parts to maintain their effectiveness.
- Consider making multiple clamps for different track lengths or angles to accommodate various woodworking applications.
By following these tips and tricks, you can create plunge saw track clamps that provide the stability and control you need for your woodworking projects. Enjoy the enhanced precision and ease of use that these clamps can offer!
