I have a larger than normal need of doors, and I am tired of my regular clamps. I do not have room for a typical door clamp setup, so I fashioned my own based on some other designs I found. It was a fun CNC project. I suppose I could just order the doors, but where is the fun in that?
Started with a piece of Baltic Birch with a shop grade laminate on one side. I drilled 90 20mm dia holes and cut out the sheet in about 25min. I used 20mm diameter so I could use my Festo clamps. The dog hole spacing does not match the Festool bench because I would need too much air hose or quick connects to use the cylinders on the festool bench below. Cutting the sheet was a bit slower because I used a pecking drill routine. I have not drilled much laminate, and I didn't want to do this twice.
PEG-HoleCut.jpg
Next, I needed a base to bolt to my air cylinders. Here is a picture from milling 3/4" aluminum down to what I needed. The stock was held in using the vacuum, and a board screwed to the base for added comfort.
AlumBaseCut.jpg
Here are the two parts after they were cut out from the rough stock. The plate was counter bored and center punched for final drilling on my drill press.
AlumBase.jpg
Here is one base attached to the cylinder. These cylinders extend 4", and will apply 310lb clamp force at 90psi. You can order cylinders that have a spring release to open instead of using air. That saves a bit of tubing, but it cylinder was not a standard part at McMaster, so I opted to add the extra tube.
Cylinder.jpg
Here is the assembled jig. When not in use the jig can be easily moved up the wall so it hangs tight to the wall out of the way. I know the professional versions have clamps in the opposite direction as well, but I found examples without the extra cylinders that seem to work. I can add two more cylinders later if need be.
Compl.jpg
Here is a door I had sitting on a bench clamped in the table. I am not quite done with the steel plate the bolts to the cylinder. It turned out I did not have a counter sink for 1/2" diameter bolts. I also think I will add a wood plate to the front of it so I do not have to fiddle with the wood spacer. I can see that will be a nuisance.
Clamped.jpg
Anyway, I thought I would share with the gang here.