DIY

We make G-shaped mini-clamps from metal (no welding)

Hello, dear readers and homemade products!
One of the indispensable helpers in almost any workshop are clamps. For all their simplicity, these tools are quite expensive, and in the workshop they are “never enough.”
In this article, Neil, the author of the YouTube channel “Pask Makes”, will tell you how he made a set of small and effective G-clamps.
Making G-shaped mini-clamps from metal (without welding) This project is relatively labor intensive, and can be completely completed with a small set of tools.
Materials needed for DIY.
– Steel strip 50 × 12 mm, bar
– Bolts, brass bar, steel ball
– Machine oil, sandpaper, acetone, spray paint.
Tools used by the author.
– Screwdriver
– Bits for metal
– Drills for metal
– Petal grinding attachment for screwdriver
– Grinder, hacksaw for metal
– Pliers, nippers, vice, file, hammer
– Ratchet tap holder, tap
– Digital caliper, automatic center punch
– Wrenches, square.
Manufacturing process.
So, the material for the body of this clamp will be a strip of low-carbon steel with a cross section of 50X12 mm.
From it, the author cuts off a workpiece 55 mm long with a hacksaw for metal.
Making mini G-clamps made of metal (without welding)  Making mini G-clamps from metal (no welding) Then the workpiece is processed with a file.
We make G-shaped mini-clamps from metal (without welding) We make G-shaped mini-clamps from metal (without welding) To select material from the center of the steel profile, you can drill several holes and then cut them with a hacksaw. The result is a jagged, jagged edge that requires significant filing.
We make G-shaped mini-clamps from metal (without welding) However, the author chooses a different solution with a metal crown he drills one large central hole. A regular screwdriver is enough here.
We make G-shaped mini-clamps from metal (without welding) Making mini G-clamps made of metal (without welding) Making G-shaped mini-clamps from metal (without welding) Now you need to remove the jumper so that both parts are symmetrical. Marking is done using a square and a caliper .
We make G-shaped mini-clamps from metal (without welding) Making mini G-clamps made of metal (without welding)  Making G-shaped mini metal clamps (no welding) Making mini G-clamps made of metal (without welding) And now the general contours of the future clamp are outlined. Next, a bit of filing to remove any sharp edges and jagged edges.
We make G-shaped mini-clamps from metal (without welding) Making G -shaped mini-clamps made of metal (without welding) We make G-shaped mini-clamps from metal (without welding) The next step is to drill a hole for the pressure screw in the lower jaw of the clamp. The hole should be made at a perfectly right angle – this is a fundamental point. Of course, the whole operation could be carried out on a drilling machine, but the author acts within the stated conditions: only hand tools.
First, with the help of automatic core , the center of the hole is marked. The first pass is made with a 4 mm drill.
The master made a simple jig for drilling at right angles. To do this, he glued a couple of pieces of 4 mm plywood, lays it underneath and attracts with a clamp. Thus, the drill gets a natural angle limitation in the vertical plane.
Observing a right angle in the horizontal plane is quite simple – you need to hold it parallel to the nearest vise jaw.
Making mini G-clamps made of metal (without welding)  Making G-shaped mini metal clamps (no welding) Making mini G-clamps made of metal (without welding) We make G-shaped mini-clamps from metal (without welding) Making G -shaped mini-clamps made of metal (without welding) Then the finished hole is reamed to the diameter 6.8 mm.
Making G-shaped mini-clamps from metal (without welding) Before using the tap and tapping, the author uses a larger drill to chamfer the hole.
Tapping is made easier by using a ratchet holder .
We make G-shaped mini-clamps from metal (without welding) Making G -shaped mini-clamps made of metal (without welding) Making G-shaped mini-clamps from metal (without welding) Then, with the same file, the outer corners are rounded off.
 We make G-shaped mini-clamps from metal (without welding) By heating one corner of the part, Neil puts his own stamp on it.
< img class = "aligncenter" alt = "We make G-shaped mini-clamps from metal (without welding)" src = "https://usamodelkina.ru/uploads/posts/2021-06/1625086470_sf-134.jpg"/> Making G-shaped mini-clamps from metal (without welding) Making G -shaped mini-clamps made of metal (without welding) This is followed by grinding the body on fine-grained sandpaper with water. The inner radius is ground using a flap drum for a screwdriver.
Making mini G-clamps made of metal (without welding) We make G-shaped mini-clamps from metal (without welding) Making G -shaped mini-clamps made of metal (without welding) Now you need to make a hold-down washer. On a similar prototype, it was made from an M6 nut. However, in this project the author intends to use for this purpose a steel bar with a diameter of 12 mm.
First, a 7 mm hole is made in the bar, and then an additional 7.5 mm recess is made about a couple of millimeters deep.
 Making G-shaped mini-clamps from metal (no welding) We make G-shaped mini-clamps from metal (without welding) Making G -shaped mini-clamps made of metal (without welding) Making mini G-clamps made of metal (without welding)  Making G-shaped mini metal clamps (no welding) Making G-shaped mini-clamps made of metal (without welding) Holding the washer on the bolt with a nut, you can grind it with < u> screwdriver .
We make G-shaped mini-clamps from metal (without welding) To fix the washer on the clamping screw, first cut a small projection on the bolt leg. A craftsman screws a pair of nuts onto the bolt, which will serve as a natural limitation for the file and thereby provide the desired processing height for the screw leg.
We make G-shaped mini-clamps from metal (without welding) Making G -shaped mini-clamps made of metal (without welding) We make G-shaped mini-clamps from metal (without welding) The next step is to drill out the center in the screw leg, leaving a small rim.
Later, when the washer is put on, this rim will need to be flared in order to fix the washer in this position, and at the same time it was able to freely rotate.
We make G-shaped mini-clamps from metal (without welding) Making G -shaped mini-clamps made of metal (without welding) Making mini G-clamps made of metal (without welding)  Making G-shaped mini metal clamps (no welding) A through hole is now drilled through the bolt head. Later, a 3-mm brass bar clamp knob will fit here.
We make G-shaped mini-clamps from metal (without welding) We make G-shaped mini-clamps from metal (without welding) Both ends of the wrench should be flattened slightly to prevent the rod from jumping out of the hole.
We make G-shaped mini-clamps from metal (without welding) Making G-shaped mini-clamps made of metal (without welding)  Making G-shaped mini metal clamps (no welding) Making mini G-clamps made of metal (without welding) Now you can put a pad on the screw and flare the rim. For this, a ball bearing and a powerful clamp are taken, since a rather large force is required.
Making mini G-clamps made of metal (without welding)  Making G-shaped mini metal clamps (no welding) And now, the first clamp is ready!
Making mini G-clamps made of metal (without welding) The entire technological process can be repeated on heavy equipment. Certain stages of work will undoubtedly pass much faster, and the quality will obviously increase.
So, for cutting blanks, the author uses a miter saw. Grinding the edges is performed on a band machine.
Making G-shaped mini-clamps from metal (without welding) We make G-shaped mini-clamps from metal (without welding) Making G -shaped mini-clamps made of metal (without welding) Of course, drilling with a crown is much easier with using the machine.
We make G-shaped mini-clamps from metal (without welding) Making G -shaped mini-clamps made of metal (without welding) prefers hand, knife.
Making mini G-clamps made of metal (without welding)  Making G-shaped mini metal clamps (no welding) The alignment of the pressure pad is also carried out on the grinder, while you have to cool the part with water.
We make G-shaped mini-clamps from metal (without welding) We make G-shaped mini-clamps from metal (without welding) Making G -shaped mini-clamps made of metal (without welding) Having prepared a lot of cases at once, the burner can not be extinguished – while one part is heated, a stamp is put on the other.
We make G-shaped mini-clamps from metal (without welding) We make G-shaped mini-clamps from metal (without welding) Making G -shaped mini-clamps made of metal (without welding) To avoid marking and centering center, the master fixed an additional stop in the form of a drill near the machine vice – it helps to center the part.
Making mini G-clamps made of metal (without welding)  Making mini G-clamps from metal (no welding) Making mini G-clamps made of metal (without welding) Finishing stages of grinding remain, and the body can be blued or painted.
We make G-shaped mini-clamps from metal (without welding) Making G -shaped mini-clamps made of metal (without welding) Before applying a layer of spray paint, master degreases parts in acetone.
Making mini G-clamps made of metal (without welding)  Making mini G-clamps from metal (no welding) The pin is also formed manually, with a file.
 Making G-shaped mini-clamps from metal (no welding) < a href = "https://usamodelkina.ru/uploads/posts/2021-06/1625086493_sf-356.jpg" rel = "prettyPhoto">We make G-shaped mini-clamps from metal (without welding) However, a jig in the form of a strip with a hole is already used for drilling. Having centered one of the bolts, the next ones just need to be changed and tightened in the jig with nuts.
 We make G-shaped mini-clamps from metal (without welding) Making mini G-clamps made of metal (without welding) We make G-shaped mini-clamps from metal (without welding) The same jig is also suitable for drilling a hole for a crank – the device simply turns in a vice 90 degrees.
 Making G-shaped mini-clamps from metal (no welding) Making mini G-clamps made of metal (without welding) Drilling a blank for washers is also less problematic – you can make very deep axial hole in the bar.
We make G-shaped mini-clamps from metal (without welding) And the grinding process is accelerated if you pre-process the entire surface of the bar.
 We make G-shaped mini-clamps from metal (without welding) Before cutting off the nut, you may have to remove the chamfer.
Making mini G-clamps made of metal (without welding)  Making mini G-clamps from metal (no welding) Another conductor with a limiter is made from a corner.
 We make G-shaped mini-clamps from metal (without welding) We make G-shaped mini-clamps from metal (without welding) Making G -shaped mini-clamps made of metal (without welding) We make G-shaped mini-clamps from metal (without welding) It is almost useless to paint the pressure washers – the paint will quickly peel off them. The “Super Blue” chemical bluing method is better suited here. After rinsing and drying, the parts are rubbed with oil.
Making G-shaped mini-clamps from metal (without welding) Making G -shaped mini-clamps made of metal (without welding) The author makes cross cut.
We make G-shaped mini-clamps from metal (without welding) Making G -shaped mini-clamps made of metal (without welding) Making mini G-clamps made of metal (without welding) Finally, the set of clamps is ready. All that remains is to secure the knobs.
We make G-shaped mini-clamps from metal (without welding) Making G -shaped mini-clamps made of metal (without welding) Thank the author for the master class on making small G-clamps.
Making G-shaped mini-clamps from metal (without welding) Making G -shaped mini-clamps made of metal (without welding)  We make G-shaped mini-clamps from metal (without welding) Good mood, good health, and interesting ideas to everyone!
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Author's video can be viewed here.

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