Clamp Rack Router Template

thingiverse

This is a router template for cutting the pattern for a clamp rack for F-style clamps. This pattern is used to cut the 'shelves' that hold the clamps. The slots are each 5/16" wide, and 2 1/4" deep, and spaced 1 1/2" on center. Originally, I made this with a shallower depth, but found that it didn't do a very good job of holding the clamps; so I went back and made a deeper ne that worked much better. To use the template, first you will need to glue up a suitable shelf. I laminated 4 pairs of 1/2" pieces of plywood, cut into 24"x4" strips. This gave me 4 shelves that were an inch thick, and super strong to resist flexing. Next, I marked out the innermost cuts. To save myself burning through a LOT of router bits, I pre-drilled each channel, and then rough cut the remainder of each channel with the band saw. Once all the individual channels / slots were rough cut, I could use the router template and a palm router with a 1/4" up-spiral, flush trim bit to clean up each channel, and make them look uniform. Once they were all cleaned up, I hand sanded everything to get rid of any sharp edges, and give each shelf a 'smooth to the touch' finish. Next, I cut 4 dados in a piece of 24"x48"x1/2" contractor-grade plywood (what used to be the cheaper stuff). Previously I had spread the bulk of the clamps on the floor to figure out the ideal placement of each shelf. Once those dados were cut, it was just a matter of gluing up and press fitting each of the shelves into their predetermined dado slot, adding a little insurance by countersinking some 2 1/2" deck screws in from behind, and clamping the heck out of it all until cured. For additional added insurance, I also glues in some bracing I whipped up by cutting down some 1x4 scraps I had in the fire pile. Finally a quick sanding, a coat of Minwax wipe on Gunstock Stain, and a few coats of poly, and we were off to the races. I sized this clamp rack to hold up to 60 F-Style clamps, and to work with Bessey, Jorgensen, Harbor Freight, Crafstman and other clamp manufacturers. The template is sized to be printed using a Prusa Mini, but to make the job a little easier, I would have used larger pattern and printed it on a larger printer. That would have saved me a lot of repositioning of the template every few cuts. ...but if I had a proper router table, I suppose it would be a lot easier (and probably safer) to use the template. Enjoy! ...and you can never have enough clamps!