For example, the Panavise Junior vise is inexpensive and very handy, but is a self-contained unit: it includes both a base and vise. Since I have a standard low-profile base I use with other vise attachments, I wanted to see if I could make my Junior vise fit it to give me the added flexibility of the standard base and reduce the number of things I have around my workspace.
Turns out Panavise had the same idea and now sells just the Junior vise head, but I already had mine and didn't want to buy another ... so, here's how I did it.
Step 1: Preparation
Before diving in, it's a good idea to take the head off the Junior vise just to see how it goes together. You'll see that the head has a pincer that fits into the shaped attachment on the base. That's what the groove in the rod is for.
The standard PanaVise base is just a simple clamp that holds a 5/8" rod.
Step 2: Saw Off the End of the Rod
Step 3: Make a Groove Around One End
Then, I just used the hack saw to saw the groove. Make sure not to go too deep. If you do, the Junior end won't clamp very well. Better to make it too shallow then go back and adjust it rather than the other way. In fact, when I first tried this, the groove was too deep and I had to start over.
When you have the groove cut, shape it using the triangle file. When you're all done, the Junior top should fit into the groove and when clamped down, there should be a small gap at the base of the top (see the photos).
Step 4: Cut the Rod to Length
As before, clamp it into the mitre box and saw off the piece. Then, de-burr it using the file. Viola! You're done except for putting it together.