Wagon Vise Retrofit Installation Instructions. American Craft Woodworks. Wagon Vise

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Adelia Cook
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1 Wagon Vise Retrofit Installation Instructions American Craft Woodworks Wagon Vise

Wagon Vise Retrofit Installation Instructions 2 Retrofit Installation Instructions Before you get started, please read through all the installation steps beginning with the following notes 1.

2 Wagon Vise Retrofit Installation Instructions 2 Retrofit Installation Instructions Before you get started, please read through all the installation steps beginning with the following notes 1. To install this wagon vise on an existing bench, you will need to excavate the portion of the bench material where the vise operates. To clearly communicate the areas that need to be removed, I have separated the areas of excavation into three stages. 2. Because I don t know all of the skills and tools people have that will be using these instructions, I don t go into detail about the methods to accomplish the tasks. You ll need to use your tools, skills, and creativity to complete the steps as you see fit. 3. When all steps are completed, the top of the sliding dog block will sit proud of the surface of your bench by up to 1/16. This is by design, please do not correct for this during installation. The purpose of this is to allow you to plane the top of the sliding dog block perfectly flush with your benchtop after installation, then apply the finish of your choice. 4. I apologize for over- using the word excavate. 5. In step 2 you will measure out the rectangle for the first excavation. The length of the rectangle is dependent on the layout of your bench and will be the same length for all 3 stages of excavation. I have used the variable X throughout this instruction to refer to this length. To determine X for your bench, measure the distance between the clamping faces of two consecutive dog holes and add 3-1/4. This is your minimum X. Then measure the minimum X from the inside edge of your end apron, and determine the distance to the next closest dog hole. Add this amount to your minimum X, and subtract 1. This is your final X. For example, if there is 6 between clamping faces of two dogs, you should have 9-1/4 minimum X. Measure 9-1/4 from the end apron. If the next closest dog is 3 further, add that to 9-1/4 for 12-1/4, then subtract 1 for an X of 11-1/4. Substitute 11-1/4 for X throughout the instruction.

3 Wagon Vise Retrofit Installation Instructions 3 I have an X length calculator on my website that will do the calculation of your X for you. Just go to Have the following dimensions in inches: 1. End Apron Thickness 2. Distance from the end of the bench to the clamping face of your first bench dog 3. Distance between clamping faces of two consecutive bench dogs Recommended Tools to Complete this Installation: Ruler Tri or Combo Square Electric Router or drill and chisel (for excavation steps 3, 7, 10) Mallet or hammer (steps 3, 7, 10, 14) 1/8 Brad Point drill bit (steps 12, 15) Medium sized Phillips head screwdriver (steps 13, 19) 2 Forstner drill bit (step 16) 1-1/4 Forstner drill bit (step 17) Two 1/2 wrenches, or ratchet and 1/2 socket (step 20) 5.5mm Allen wrench (step 20) 9/16 wrench or adjustable wrench (step 20)

4 Wagon Vise Retrofit Installation Instructions 4 1. Mark a centerline on your benchtop that represents the centerline of the dog holes.

5 Wagon Vise Retrofit Installation Instructions 5 2. Measure and mark a rectangle (depicted in red in the image below) on your benchtop that s width extends 1-1/8 to each side of the dog hole centerline, and that s length starts at the inside edge of the end apron and extends X. The rectangle should measure X x 2-1/4. *Note* I do my best to make the sliding dog blocks exactly 2-1/4 wide, but there may be some variation. Please test the width of the sliding dog block you received and adjust the width to the exact width of your sliding dog block.

6 Wagon Vise Retrofit Installation Instructions 6 3. Excavation #1: Excavate the rectangle ¾ deep into the benchtop. The excavated section is where the top of the sliding dog block will fit, and it should have a snug fit but slide smoothly. Test fit the width of the excavation along its full length by placing the sliding dog block up- side- down with its top fitting into the excavation.

7 Wagon Vise Retrofit Installation Instructions 7 4. Flip the benchtop over, or the whole bench if you must. As a last resort prepare to work from the bottom.

8 Wagon Vise Retrofit Installation Instructions 8 5. As on the top, mark the dog hole centerline on the bottom.

9 Wagon Vise Retrofit Installation Instructions 9 6. Measure and mark a rectangle (depicted in red in the image below) on the underside of the benchtop that s width extends 1-5/8 to each side of the dog hole centerline, and that s length starts at the inside edge of the end apron and extends X. This rectangle should measure X x 3-1/4. *Note* in the image below, the rectangle extends over the edge of the supporting dog hole board. This is just for illustration purposes, and the excavation in the following step will include the portion of benchtop below the overhanging part of the rectangle.

Wagon Vise Retrofit Installation Instructions 10 7. Excavation #2: Excavate the marked section to meet the depth of the section that was removed from the top.

10 Wagon Vise Retrofit Installation Instructions Excavation #2: Excavate the marked section to meet the depth of the section that was removed from the top. This will leave you with an excavated area that is X long and 3-1/4 wide, and two upper rails that are ¾ thick and ½ wide. The image below has views of the excavation from two opposite perspectives.

Wagon Vise Retrofit Installation Instructions 11 8.

11 Wagon Vise Retrofit Installation Instructions At this point you should be able to test fit the sliding dog block into the excavation. Ensure it fits and slides smoothly. Once fit, remove the sliding dog block.

Wagon Vise Retrofit Installation Instructions 12 9.

12 Wagon Vise Retrofit Installation Instructions On the underside of the benchtop adjacent to the long edge of the excavation opposite from the front apron, measure and mark a rectangle (depicted in red in the image below) that s width starts at the long edge of the excavation and extends ¾, and that s length starts at the inside of the end apron and extends X. You should have a rectangle that is X x ¾.

Wagon Vise Retrofit Installation Instructions 13 10.

13 Wagon Vise Retrofit Installation Instructions Excavation #3: Excavate this section down to ¾ above the top rail. For example, if your benchtop is 2-3/4 thick, this excavation should be 1-1/4 in depth.

Wagon Vise Retrofit Installation Instructions 14 11.

14 Wagon Vise Retrofit Installation Instructions Position Lower Rail #2 against the sliding dog block between the nut and the attached rail, then lower the sliding dog block into the excavation. Finally, slide Lower Rail #1 between the front apron and the sliding dog block so that the screw slots are up. See image below for clarification.

Wagon Vise Retrofit Installation Instructions 15 12.

15 Wagon Vise Retrofit Installation Instructions Using a punch or the tip of a brad point drill bit, mark the center of each of the screw slots of lower rail #1 into the inside face of the front apron. Also mark the center of the screw holes of lower rail #2 into the benchtop. Remove the sliding dog block and lower rails, then drill pilot holes that are ¾ deep at each of the six marks with a 1/8 drill bit.

Wagon Vise Retrofit Installation Instructions 16 13. Apply furniture wax (optional) to the upper and lower rails in the benchtop as well as the rails attached to the sliding dog block.

16 Wagon Vise Retrofit Installation Instructions Apply furniture wax (optional) to the upper and lower rails in the benchtop as well as the rails attached to the sliding dog block. Return the sliding dog block and both lower rails into their respective positions. Using the provided 1-1/4 screws, attach both lower rails to the bench so the screws seat snug, but not very tight. Ensure the sliding dog block slides smoothly.

Wagon Vise Retrofit Installation Instructions 17 14.

17 Wagon Vise Retrofit Installation Instructions Take the vise screw and thread it into the vise nut backwards so the small metal screw head in the end of the vise screw protrudes the vise nut by at least ¼.

Wagon Vise Retrofit Installation Instructions 18 14- continued. Slide the sliding dog block toward the end apron until the metal screw head is touching the apron.

18 Wagon Vise Retrofit Installation Instructions continued. Slide the sliding dog block toward the end apron until the metal screw head is touching the apron. Using a piece of scrap to protect the other end of the vise screw, give the vise screw a sharp tap with a mallet. The goal of this step is to make a small impression in the end apron with the metal screw head of the exact center of the vise screw for drilling. Once the impression is made the small metal screw may be removed from the vise screw if desired.

Wagon Vise Retrofit Installation Instructions 19 15. Remove vise screw, lower rails, and sliding dog block.

19 Wagon Vise Retrofit Installation Instructions Remove vise screw, lower rails, and sliding dog block. Drill a 1/8 pilot hole through the end apron at the center of the impression left from step 14. Ensure the pilot hole is drilled perpendicular to the face of the end apron.

Wagon Vise Retrofit Installation Instructions 20 16. Using the pilot hole to center your Forstner bit, drill 2 wide counter bores in each side of the end apron that are 1/8 deep.

20 Wagon Vise Retrofit Installation Instructions Using the pilot hole to center your Forstner bit, drill 2 wide counter bores in each side of the end apron that are 1/8 deep. *Note* It is important not to exceed 1/8 deep on these holes. Sneak up on this depth. It s better to be too shallow than too deep here. In the case that these holes are a little shy of 1/8, you may have trouble getting the hand wheel bolt through the vise screw. In this case a few plane passes on the inside face of the hand wheel may help bring the bolt through the vise screw.

Wagon Vise Retrofit Installation Instructions 21 17.

21 Wagon Vise Retrofit Installation Instructions Using the pilot hole to center your Forstner bit, drill a 1-1/4 hole through the end apron.

Wagon Vise Retrofit Installation Instructions 22 18. Thread vise screw into the vise nut in the correct direction the full length of the vise screw.

22 Wagon Vise Retrofit Installation Instructions Thread vise screw into the vise nut in the correct direction the full length of the vise screw. This time, the threads of the vise screw should thread directly into the threads of the vise nut, rather than the backside, which is hollowed out.

Wagon Vise Retrofit Installation Instructions 23 19. Install one thrust bearing set (washer/bearing/washer) onto the non- threaded end of the vise screw.

23 Wagon Vise Retrofit Installation Instructions Install one thrust bearing set (washer/bearing/washer) onto the non- threaded end of the vise screw. Return sliding dog block and both lower rails into their respective positions. Install the screws for both lower rails and tighten them so the rails are securely in place, but be careful not to over- tighten and strip the screw holes. *Note* Gluing the lower rails in place is an option, but not recommended. The sliding action of the vise may be loose or tight due to seasonal movement. Leaving the option to loosen screws and adjust is recommended.

Wagon Vise Retrofit Installation Instructions 24 19- continued. Slide the sliding dog block assembly toward the end apron, inserting the non- threaded end of the vise screw through the hole.

24 Wagon Vise Retrofit Installation Instructions continued. Slide the sliding dog block assembly toward the end apron, inserting the non- threaded end of the vise screw through the hole. The thrust bearing and washers should seat in the 2 counter bore made in step 16, but should be proud of the surface of the end apron just slightly. Install the second thrust bearing set on the vise screw, on the outward face of the end apron.

Wagon Vise Retrofit Installation Instructions 25 20. Attach the hand wheel to the vise screw with the provided 5/16 bolt, washers, and locknut.

25 Wagon Vise Retrofit Installation Instructions Attach the hand wheel to the vise screw with the provided 5/16 bolt, washers, and locknut. Attach the knob to the hand wheel with one of the provided bearings on each side of the hand wheel, and the locknut installed nylon side in, as pictured. Adjust the nut so the knob is not loose, but still spins freely. See full description in appendix A.

Wagon Vise Retrofit Installation Instructions 26 21. Turn the benchtop over and plane or chisel the sliding dog block flush with the benchtop.

26 Wagon Vise Retrofit Installation Instructions Turn the benchtop over and plane or chisel the sliding dog block flush with the benchtop. Apply the finish of your choice to the top of the sliding dog block. Test your new wagon vise and ensure it clamps securely and has the full range of motion. The final step is to give me feedback about your new vise. If you like it, please let me know by giving it a 5 star rating on the sale page. If there s anything you don t like about it, or have any questions about, please me and let me make it right. I ll make sure you re 100% satisfied or give you a full refund.

27 Wagon Vise Retrofit Installation Instructions Thanks for buying the American Craft Woodworks Wood Screw Wagon Vise. I hope you get many years of use and enjoyment from this vise. If you love your new vise, please spread the word.

28 Wagon Vise Retrofit Installation Instructions 28 Appendix A Assembling the hand wheel To attach the free wheel knob to the hand wheel, follow these steps.

29 Wagon Vise Retrofit Installation Instructions 29 Remove the locknut and bearings from the knob bolt. Place one bearing in the inset on the outside face of the hand wheel.

30 Wagon Vise Retrofit Installation Instructions 30 Insert the knob bolt through the hole.

31 Wagon Vise Retrofit Installation Instructions 31 Turn the hand wheel over, while holding the knob in the hole and place the second bearing over the bolt. Ensure the bearing comes to rest in the inset.

32 Wagon Vise Retrofit Installation Instructions 32 Thread the locknut onto the bolt, nylon end first. The threads in the nylon should already be cut when you receive your vise kit. This is backward to the typical installation, but the lip on the nylon side of the locknut is used to ensure the bearing is operating correctly.

Wagon Vise Retrofit Installation Instructions 33 Use a 5.5mm Allen wrench and a 9/16 wrench, or adjustable wrench to tighten the locknut onto the knob bolt.

33 Wagon Vise Retrofit Installation Instructions 33 Use a 5.5mm Allen wrench and a 9/16 wrench, or adjustable wrench to tighten the locknut onto the knob bolt. Tighten slowly, and stop as soon as the knob does not spin freely. Back the nut out approximately 1/16 of a turn. The knob is set correctly when it has no slop, but spins freely.

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