Want to make corner jig/clamp

admin

I picked up a couple of cheap 3" C-clamps from Horror Freight today and planned on making some type of corner jig similar to the one shown here.  http://makezine.com/projects/welding-a-jig/Will be very simple but wondered if there might be better styles or designs out there.  Have any of you built something similar?
Reply:http://www.zorotools.com/g/00115929/k-G5018447?utm_source=google_shopping&utm_medium=cpc  &utm_campaign=Google_Shopping_Feed&kw={keyword}&gc  lid=CM6ukJyZmL0CFRQV7AodqBAAhAI have one of these and it works great for small stuff most of the time.  If you are a capable welder then I suggest you enhance your welding experience by making your own tool.  It's the great twofer that the blacksmiths gave us, first we have the fun of making the tools required to have the thrill of making the stuff.life is good
Reply:I've never had any luck when guys bought HF clamps for use as jigs. The metal doesn't weld well and the joints always end up brittle. As soon as you apply any decent pressure to the clamps, the welds tear out. MAybe the way they use the jig might be better than when we cut the bottoms off the clamp, I don't know. Always seems that using decent grade clamps for jigs is worth the money..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:The purpose of the thread is because I want to create my own tool.  I realize that most harbor freight stuff is marginal or just downright crappy, but I just couldn't justify buying high grade clamps for a small project like this.  It would put the cost of materials higher than buying a purpose built clamp.  Ultimately I'm trying to figure out if there might be better clamp designs out there I can use.
Reply:Understood. My point is that you may not have success with the project using HF clamps, especially if you cut and weld them.The reason I know this is because of the exact reason you  bought these clamps.  Jigs seem to be a perfect use for cheap "disposable" clamps. However if the clamps don't stay welded, you just waste your time on the project. Been there done that with HF clamps.When you decide how to do the jig, don't just chop off the clamp and use the threaded portion as the chances of it not working are high. It would be better if you keep the clamps as intact as possible even if it makes the jig a bit clunky. Otherwise you just might as well chop up the clamps and toss them in the trash and not waste the time welding them.I'm always keeping my eyes open at yard sales and flea markets for beat up old clamps that are good for  stuff like this. Semi decent quality and inexpensive enough to make it worth while..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Originally Posted by DSWI'm always keeping my eyes open at yard sales and flea markets for beat up old clamps.
Reply:Maybe I'm not getting it, but it seems to me that the angle pieces welded onto the flat bar are the only parts that are actually REQUIRED to be welded in place for this to work.  The C-clamps would be just as effective if simply tightened into place on whatever you are wanting to hold in alignment, as they would if they are welded to the flat bar.  If it's because you think you need 2 hands to operate the C-clamp and a third hand to hold whatever in place until you tighten the clamp, why not just use a vise-grips (third hand) to hold the whatever until you tighten the C-clamps?
Reply:Originally Posted by walkerweldMaybe I'm not getting it, but it seems to me that the angle pieces welded onto the flat bar are the only parts that are actually REQUIRED to be welded in place for this to work.  The C-clamps would be just as effective if simply tightened into place on whatever you are wanting to hold in alignment, as they would if they are welded to the flat bar.  If it's because you think you need 2 hands to operate the C-clamp and a third hand to hold whatever in place until you tighten the clamp, why not just use a vise-grips (third hand) to hold the whatever until you tighten the C-clamps?
Reply:I'm all for making your own tools and I've had this type of fixture on my list for a while.With that said, check these out: http://www.northerntool.com/shop/too...3562_200403562I'm thinking about buying 4 of these.GravelThe difference between theory and practice is that in theory there is no difference.
Reply:I have the BESSEY ones similar to what GRAVEL posted. I had them for many years and hard to  be beat. They are pricey but are super time savers. Here's posts that may help. http://weldingweb.com/vbb/showthread.php...t=angle+clampshttp://weldingweb.com/vbb/showthread.php...t=angle+clamps Here's the clamps, which I did buy from Amazon but at the time not this expensive. I have 4 of these small ones http://www.amazon.com/Bessey-WSM-9-7.../dp/B0006694FA 2 of the large, and they are BIG http://www.amazon.com/Bessey-WSM-12-.../dp/B0006694FK
Reply:Those purpose built clamps are sweet.  I'd love to have a set of 4.   But in the spirit of custom fab and making your own tools this is a small project I've been looking forward to doing.  My biggest concern with the style of clamp I posted in the topic is that by using L- channel the inside joint is not 100% square.  It has a concave bead at the intersection of the 90 degree angle.  It wouldn't matter if I was holding square tubing in the jig since it has rounded corners.  But if I was trying to hold flat stock or something with a sharp outside corner it would not be able to sit flush in the jig.  I guess I could make my own L-channel and only weld the outside joint.  I'd be concerned about warpage though.  Maybe this would be good tig welding practice on that outside joint
Reply:Originally Posted by blackwaterstoutYou are right.  Technically the C clamps do not need to be welded to the jig.  Welding them on should make it easier to use.  I'm not going to alter the clamp other than just removing a little paint at the weld location.  I do not plan to cut the clamp like DSW did.  I think this will work fine.
Reply:I have 2 like Gravel's. 1 Hobart and 1 Pittsburgh HF unit. Always on the lookout for more Hobart ones when the come on sale at TSC. Last time they only had 1.Airco Heliweld II AC/DC HomeMade Wire FeederLincoln 255PLincoln HD130Everlast PP804x8 CNC TableWelding helps me build my hobbies and takes up time on the side.
Reply:Originally Posted by DSWI've never had any luck when guys bought HF clamps for use as jigs. The metal doesn't weld well and the joints always end up brittle. As soon as you apply any decent pressure to the clamps, the welds tear out. MAybe the way they use the jig might be better than when we cut the bottoms off the clamp, I don't know. Always seems that using decent grade clamps for jigs is worth the money.
Reply:Bandaid and Burp. I'll be honest and say that though had not occurred to me since I seldom have a need to braze things, though I have all the gear and rods on hand. It would however have been the perfect use for it. I'll have to keep that in mind if the situation arises again. Sometimes we just get locked into what we do all the time and forget there are other options available to us. Time to remember to think outside the box..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Originally Posted by blackwaterstoutMy biggest concern with the style of clamp I posted in the topic is that by using L- channel the inside joint is not 100% square.  It has a concave bead at the intersection of the 90 degree angle.  It wouldn't matter if I was holding square tubing in the jig since it has rounded corners.  But if I was trying to hold flat stock or something with a sharp outside corner it would not be able to sit flush in the jig.  I guess I could make my own L-channel and only weld the outside joint.  I'd be concerned about warpage though.  Maybe this would be good tig welding practice on that outside joint
Reply:Hello blackwaterstout, here's a pic. of a right-angle clamp that I built some time ago. Made from cold-rolled bar stock. Good luck and best regards, Allan Attached Imagesaevald
Reply:Originally Posted by aevaldHello blackwaterstout, here's a pic. of a right-angle clamp that I built some time ago. Made from cold-rolled bar stock. Good luck and best regards, Allan
Reply:Originally Posted by GravelI'm all for making your own tools and I've had this type of fixture on my list for a while.With that said, check these out: http://www.northerntool.com/shop/too...3562_200403562I'm thinking about buying 4 of these.
Reply:I made one over the summer with some scrap and an old screw vise assembly from an old chop saw. Pretty happy with it fit up is about perfectly square. After a couple tacks to hold it always re-check with a good square, so far hardly any adjusting.Why spend alot of money if you can make one for little to no money.  Iam not building a rocket ship in my garage.Precision tig 225Millermatic 185 w/ spoolgunLincoln 140Dewalt cold saw
Reply:Nice. I really like that one..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Originally Posted by DSWNice. I really like that one.
Reply:I have used a few of the HF 4 inch copper screw C clamps for Hi-Lo clamps and just used 7018 to weld to the half inch flat I used on the bottom. Just a small gusset on the back. I have broke the short weld to hold them down and no problem with the clamp. Maybe I used a different clamp that you have used.Miller xmt304,  Miller S22 p12, Miier Maxstar SD, Miller 252 w 30A, Miller super32p12, Lincoln Ranger 9, Thermal Arc 181I with spoolgun, Hypertherm 10000 ,Smith torches. Esab 161lts miniarc.
Reply:Vettersjake,I really like that clamp!  Thanks for the idea.jerry30+ yrs Army Infantry & Field Artillery, 25 yrs agoMiller 350LX Tig Runner TA 210, spool gunLincoln 250/250 IdealArcESAB PCM 500i PlasmaKazoo 30"  vert BSKazoo 9x16 horiz BSClausing 12x24 lathe20T Air Press
Reply:I made my jig tonight.  Everything went well except for welding the clamps onto the jig.  Before welding I ground the paint off the clamp near the weld location but it didn't weld worse a darn.  I guess those clamps are made of cast iron or some cheap cast Chinese stuff.  I used 3/32" 7018.  The amps I was using for the angle and flat stock was too high for the clamps.  So I couldn't find the correct amperage.  The welds were pretty ugly on the clamp side.  Ill see how well it holds up.vettersjake and aevaldI really like those clamps!  Great ideas.ThanksPaul
Reply:Originally Posted by vettersjakeThanks you sir. The bad thing is, fitting two different size pieces of material doesn't work too good without some  shims.
Reply:Here's a semi small one I made some time back. I can move the angle from the inner position to the outer by taking the wing bolts out, spinning the angle around. Of course you use the usual assortment of c clamps, vice grips whatever. Attached Images"The things that will destroy America are prosperity at any price, peace at any price, safety first instead of duty first, the love of soft living and the get rich quick theory of life." -Theodore Roosevelt
Reply:Braze, don't weld. I have used the drill press clamps I made in post 21 here http://weldingweb.com/vbb/showthread.php...l-press-clampsfor while and I'm not shy about snuggin them down either.Last edited by kald; 03-18-2014 at 12:16 AM.Idealarc 250AC 225SVictor OA-older made in USA stuff.And a crap ton of other stuff.
Reply:Hello again blackwaterstout, here are a few photos of a couple of other possibilities for corner jigs. These are mainly for pipe applications and one of them is well suited for different diameters. Best regards, Allan Attached Imagesaevald
Reply:How do you square the jig?Sent from my SPH-M830 using Tapatalk
Reply:Hello tapwelder, you can use a framing square and check it against the two surfaces. You could put the fixture on a flat plate standing up and slide a square up against the vertical side of the fixture and look for any gaps to check it that way. Or, you could use the fixture to tack a part on in a "T" shape and then move the fixture to the other side and slide it up against it to see if there are any gaps. Best regards, Allanaevald
Reply:Mine isn't terribly fancy, but it works nicely, and only cost a few bucks to make ;-) It gets used pretty frequently, and in fact I used it today for a slight modification of my welding bench
Reply:Originally Posted by DSWYou might find that if the clamp base had the ability to pivot that you wouldn't need the shims. That would let the clamp self center itself to adjust. I'd have to look at my buddies Bessy clamp and see how that deals with dissimilar sizes, but I believe it's thru the clamps being able to pivot tonight.