Sawhorse Clamp/vice-DIY.

The Kitsonas Clamp: A Modular €50 Heavy-Duty Sawhorse Station with an integrated vice/clamp !

Introduction

The Kitsonas clamp is a modular, high-pressure clamping system designed to turn a standard metal sawhorse into a heavy-duty workstation. By using galvanized pipe and a unique underside mounting system, it provides industrial-grade stability for approximately €50. !

Technical Performance Addendum: Kitsonas Clamp

To assist builders in evaluating this system, here are the verified performance specifications for the standard build of the vice /clamp :

1. Net Weight: Approx. 10 kg (22 lbs).
2. Note: Roughly half the weight of most commercial clamping workstations, ensuring high portability.
3. Clamping Pressure: Approx. 500 kg (1,100 lbs).
4. Capability: Industrial-grade force suitable for heavy-duty metalwork and structural glue-ups.
5. Standard Clamping Width: Approx. 68 cm.
6. Note: Fully modular; width can be increased by simply swapping the 3/4" galvanized pipe length.
7. Stability Configuration: 4-Leg Rectangular Stance.
8. Advantage: Superior lateral stability and resistance to tipping compared to common 3-leg tripod designs.
9. Compatibility: Height-adjustable to sync perfectly with a Workmate, standard workbench, or outfeed support.

⚠️ SAFETY & LEGAL DISCLAIMER (PLEASE READ)

The Kitsonas Clamp is an experimental DIY project shared for entertainment and inspirational purposes only. It has not been tested or certified by any safety organization (ISO, CE, etc.).

By proceeding with this build, you agree to the following:

1. Assumption of Risk: You build and use this system entirely at your own risk. The developer holds no responsibility for any injury, property damage, or mechanical failure.
2. Verification: You must verify the maximum load rating of your specific sawhorse and components before assembly.
3. Adult Use Only: This project is intended for competent adults equipped with proper Personal Protective Equipment (PPE).
4. Non-Commercial: This is an open-source idea; the developer receives no financial benefit from this project.
5. Always work safely and use your best judgment!

Materials and Tools

1. Chassis: One metal sawhorse (steel frame).
2. Clamp Hardware: One 3/4" pipe clamp fixture set.
3. The Bar: One 3/4" galvanized steel pipe (length determined by your project needs).
4. Mounting Blocks: Two solid wood blocks (approximately 15cm x 10cm x 5cm).
5. Fixings:
6. Four carriage bolts M8×60 (long enough to pass through the block and sawhorse frame).
7. Four wing nuts and washers (for tool-free modularity).
8. Two metal straps/brackets and wood screws (to secure the clamp head

Preparing the Mounting Blocks

1. Drill for Pipe: Drill a 3/4" (or slightly larger) hole through the center of both wooden blocks to allow the galvanized pipe to slide through.
2. Drill for Mounting: Drill two holes through the base of each block to align with the mounting holes on your sawhorse’s steel top.

Attaching to the Sawhorse

1. Place the blocks on the sawhorse and insert the carriage bolts through the blocks and the metal frame.
2. The Modular Secret: Secure the bolts from underneath using the wing nuts. This allows you to detach the entire system in seconds for portability

Seating the Clamp

1. Slide the 3/4" galvanized pipe through both blocks.
2. Attach the screw-end of the pipe clamp fixture to the front block.
3. Security Lock: Screw a metal strap over the front of the clamp fixture to lock it into the wooden cradle, preventing it from kicking out under pressure.
4. Slide the adjustable tail-stock onto the rear of the pipe

Final Adjustments

1. Scuff the Pipe: For maximum grip on slick galvanized steel, lightly sand the pipe with 80-grit sandpaper where the tail-stock clutch plates bite.
2. Modular Swap: You can now swap pipes of different lengths into this chassis depending on the size of your workpiece.
3. STORAGE. You can place a magnetic dish between the top flat surface of the metallic sawhorse and the pipe.
4. JAW PADS. You can place wood or rubber pads on the metal jaws .