Welding clamps are an integral part of any welding job. Hence, every welder must have the welding clamps ready at their disposal for use. Clamps allow you to hold the welding material tightly so that it can’t move. Thus, your welding gets easier and the result is impressive too.
While purchasing these clamps from the market can cost you up to $30, you can easily prepare them at home. The only thing you have to know is how to make welding clamps.
Actually, welding clamps manufacturing is a simple process for most welders. You have to prepare the tube first and then work on it to build the right clamp. Also, you should wear protective equipment such as goggles and gloves for safety.
When you decide to make the welding clamps at workshops or home, the process should be easy to follow and straightforward. You need not be confused with it. You should start by accumulating the items necessary to manufacturer the clamp.
Things you will require:
1) 2 large pieces of tubes
2) 2 small pieces of tubes
3) A pencil or ruler
5) Cutting torch
6) Drilling machine
7) Two previously used F clamps
We assume that things items are ready in your hand. So, now let’s proceed to the welding clamp building process.
Step 1: Ensure Safety
Before you begin to build the clamp, you must ensure safety. Thus, you should wear safety gear to protect you from any possible accidents during the process. It is essential because clamping is thought to be one of the riskiest jobs in the USA.
You should wear the following gears to initiate the process-
2. Hand gloves
4. Face shield
5. Tight shirts and pant (preferably welding pants and shirts)
Also, keep a fire extinguisher ready in case you need it. Once you have ensured all the essential safety requirements, it’s time to start the clamp building process.
Step 2: Mark the Tubes for Cutting
We have already mentioned that you will need four pieces of tubes for the purpose. These tubes are thin. Also, two are large-sized and the other two tubes are small-sized. The thickness of the tubes has a major part to play.
It should be sufficient so that one tube can pass another one and may even sit on it. When you arrange the tubes, they should form a rectangular shape. Thus, place the two larger tubes in parallel positions. Then, on the other two sides put the smaller tubes. Make sure, the tube placement is accurate and they have a snug fit.
Now, place the F clamps on either side of the larger tubes. Use the pencil or ruler to mark right where the F clamp length meets the tubes.
Step 3: Cut the Tubes
You have to mark two times on the larger tubes with the pencil or ruler according to your preferred length of the clamp. It will help you get two pieces of tubes from one large piece. Once you have marked the tubes rightly, it’s time to cut them accurately on the marked point.
You have to put the tube on the wooden bar. Make sure, the bar is flat and even. Hold on to the tube on the bar so that it doesn’t move while you cut it. Use the cutting torch to cut each tube into two equal sizes.
This way you will get four pieces of tubes which you will use to build the welding clamps.
Step 4: Work with The Smaller Tubes
Now it is time to work with the two smaller pieces of tubes. These tubes should be at least 9” long. Also, take two tubes with 5” length.
Once you have properly marked the cutting point, use the cutting torch to cut it properly. As you cut the two tubes, you will get four smaller pieces of tubes. When the cut is complete you must clean the tubes correctly to remove any dirt and debris from them.
Remember that cleaner tubes will create stronger bonds for the welding clamps.
Step 5: Drill the Holes
Next, you have to drill holes through the tubes. It is essential for screw joints and further welding of the clamp joints.
For this, pick four tubes of the same size. Put them alongside. Then, use the pencil to mark them. You should point the mark a little away from the edge. Use the drilling machine to create the holes for screw joints.
Finally, take the other two tubes that you have previously cut at 5” length. You have to attach them to the opposite corner of the bigger tubes. Check the end where you have drilled the hole and insert the smaller tubes in their opposite direction.
Once you have figured out the joining point, weld it properly. It will ensure that the connection is secure and durable.
Step 6: Create the L-Shape for The Clamp
Now, take a tube where you have drilled the bigger hole a few moments earlier. Check where the hole is and insert the long 9” tube through it. Secure the connection by welding it properly. Follow the same way to connect and weld the other 9” tubes with the bigger tubes.
Make sure two tubes are thinner so that they can insert into the other tubes. This way you can create the handles for the clamp.
Step 7: Finish Up the Job
When you have inserted the thinner tubes into the other tube, it should take an F-shape. Now, weld all the vacant places and use a metal place to fill up space. However, the edges of the clamp will still be rough and it may cut your hands if not treated properly.
So, it is time to get on with the grinder. Use it to remove the sharpness from the edges. This way you will have two large F-shaped tubes and two small F-shaped tubes. Insert metal plates into the thin F-shaped tubes and fill them properly.
Insert it inside the bigger tubes. You should also attach another metal plate to fill its gap.
Finally, use a screwdriver to insert the nuts and tighten them properly. Congrats- your F-shaped welding clamp is ready for work.
A welding clamp isa must-have equipment for welders. The clamp securely holds the working material and allows you to work with free hands. Also, you won’t need to hold the welding material with your hands which potentially runs the risk of burning your hands.
These steps on how to make welding clamps should meet your requirements of building the DIY clamp at home. Additionally, you may consider adding cushions on each side of the clamp. It will prevent the welding clamp from creating scratches on the welded surface.