Lee Valley Tools    Woodworking Newsletter
   Vol. 5, Issue 2
   November 2010
   Shop-Built Saw Vise

  Final dry fit
  The final dry fit after cutting a chamfer-like relief in each jaw
  Sizing the spacer that keeps the jaws uniformly separated
Each jaw has a chamfer-like relief cut that should allow the user to clamp a saw in place without removing the handle (more on this later). I cut these using a bandsaw and then performed another dry fit. I glued and fastened the pieces together using wood screws in countersunk holes. These holes were later filled with hickory plugs.

Next, I sized the spacer that keeps the jaws evenly apart. It also proved a convenient place to fasten the piano hinge. In order for it to sit flush with the base of the short legs, I cut a 1/8" x 3/16" rabbet along one edge of this spacer, as well as the short-leg assembly.

I secured the jaw assemblies while installing the hinge, knowing that if I installed it incorrectly, the jaws wouldn't mate and would never hold a saw securely. With the hinge in place, I drilled the 5/16" clearance holes for the two 1/4"-20 x 4.5" long carriage bolts and installed them and the cam clamps.

Piano hinge
Installing the piano hinge under one edge of the spacer
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