Intro: THREADING AND OTHER USES OF VICE BAR
The instructable is broken into steps such that each step focusses on single application. Some applications use C-clamp. This will be evident from photographs. Explaination is given only in those applications where photographs cannot say it all. The order of applications (and hence steps) is as follows:
- Holding metal rods for making threads using dies;
- Holding sheets (wood, metal, ply, hardboard, plastic, etc.) of thickness from 1 mm to 2" (maximum thickness depends on the length of M6 bolt used; but longer bolt means more screwing and unscrewing);
- Holding wood stocks;
- Holding M.S. and alumunium stocks of various cross-sections;
- For bending sheet metal;
- For holding wood for planing, filing, drilling etc.;
- As guide for straight cuts;
- Holding page bundle;
- Holding silk screen printing screen.
- Vice bar (see instructable "VICE BAR: AN AID TO CLAMPING" for instructions to make one)
- 6mm metal rod (mild steel, alumunium or brass or any other similar metal)
- Die wrench
- Metal file
- Adjustable wrench
- Two 3" C-clamp
Step 1: HOLDING a METAL ROD FOR THREADING
CAUTION: Please use safety glasses when holding a metal rod in vertical position as shown in this step. It is risky to hold a metal rod in such a position without safety glasses as the metal rod may cause injury to eyes.
Problem of Holding
There are various ways of holding the metal rod on internet. All successfully addressed the issue of turning of metal rod due to excessive torque. Some held it in lathe spindle, some used sandpaper between vice for increasing friction, some used pipe vice for holding the rod. Somewhere I found a special attachment for bench vise for holding cylindrical objects. The methods work but are more complicated than expensive. Also they require some special tooling.
Sand paper worked for sometime and then it worn out. Test tube stand vice (it has two screws for holding circular rods perpendicular to each other) was also tried but worked only for alumunium. In that too the holding screw made a goove and the rod slipped after sometime.
So the problem is of slipping due to excessive torque. Friction alone is insufficient. This problem can be solved by two components - a flat surface filed (or grounded) on the rod and an adjustable wrench. Vice bar is used for holding in offset arrangement.
- One of the bolts of the vice bar is removed.
- The rod is inserted in that hole such that a convinient (or required) length is above the vice bar.
- A flat surface is filed right above the hole (this flat surface acts as the flat surface of a nut). It should be atleast 2 mm deep.
- The rod is held in position with an adjustable wrench using this flat surface (adjustable wrench is designed to withstand high torques).
- The end of the wrench is clamped to the vice bar using C-clamp.
Problem of Starting
This problem can be solved by grinding a 45° chamfer at that end of the rod where the threading is to be started.
Scope for improvement
- The flat surface is not aesthetically pleasing. It is avoided in case of full threaded rod where the excess rod is cut off. But in case threading is required on both sides of rod, the threading is limited by the flat surface. Also this flat surface is not aesthtically pleasing. In these cases flat surface is unavoidable. But there might be some way to avoid this flat surface.
- The diameter of the rod is fixed by the diameter of the hole.
Step 2: HOLDING SHEETS OF DIFFERENT MATERIALS
- First photo one shows multiple sheets of hard board clamped horizontally with vice bar alone (flush arrangement).
- Second photo shows copper clad board clamped horizontally with aid of C-clamps (offset arrangement).
- Third photo shows copper clad board clamped vertically with aid of C-clamps (offset arrangement).
Step 3: HOLDING PAGE BUNDLE
A bundle of pages held for cutting, glueing or binding etc. in flush arrangement.
Step 4: HOLDING WOOD STOCKS
The photograph shows holding wood stock without using any clamps in flush arrangement. Wood stock can be kept at an angle to vice bar for sawing at an angle.
It will be more convinient to hold a wood stock in the middle of vice bar.
Step 5: AS GUIDE FOR STRAIGHT CUTS
Single or multiple sheets can be cut at the same time. Angular cuts are also possible if the sheets make an angle with vice bar edge.
Flush arrangement is used.
Step 6: HOLDING PLYWOOD LIKE MATERIALS FOR PLANING
Multiple sheets clamped for planing in offset arragement. Single sheet of varying thickness can also be clamped.
Step 7: HOLDING METAL STOCKS
Offset arrangement is used.
Step 8: BENDING SHEET METAL
Bending sheet metal requires a mallet and 90° metal edge. Since, vice bar has such an edge it can be used for bending sheet metal. To avoid the problem of soft edge an angle of aluminium (or any suitable metal) is clamped to vice bar. Now this edge can be used for bending sheet metal.
Offset arrangement is used.
Step 9: HOLDING SILK SCREEN PRINTING SCREEN
It will be more convinient to hold silk screen if vice bar is on the far end of the workbench. If one can move around the workbench same vice bar can serve the purpose.
Screen is clamped in position with the help of C-clamps. An aluminium rectangular tube is fastened to screen frame with door hinges. Then the aluminium tube is clamped to vice bar. This allows lifting up of screen.
Offset or flush arrangement may be used.