"Making a Portable Clamp Rack"

        Elena places the guide rail on her marks and uses a clamp to hold it in place.

    She makes the cut. Next, she will cut the other uprights to match this one both top and bottom.

   Elena tries one of the clamp racks in place. It seems much larger than I thought. It is going to be a big clamp rack. Oh well, we can always cut it down, but we can't stretch it.     

       A new day and Andrea is here and playing with my new puppy, Gabriella.

   And back to Elena. She checks out the uprights and decides it is time to make a base for the rack.  

   We decided that white melamine particle core board would work for the base — and we have so much of it.
   Here, Elena has cut the board to size and is using my favorite Plexiglas template to round the corners.  
    

   She uses a top bearing flush cutting bit to give her the perfect finished rounded corner.

 She has installed a CMT slot cutter (5/64") in the Festool OF1400 router and sets the cutting height so that the slot will be at the mid-point of the edge.

      She uses a rubber mallet to coax the plastic edging around the base. For the corners, she has cut "vees" into the spline so that  the bumper can make the bend. She also uses a spot of CA gel at the starting point to lock it in position.
   I get the edging from Woodworker's  Hardware. It comes in a variety of widths and colors. I try to keep the 13/16" width in white and black in stock. It is inexpensive and comes in quite handy for projects like this. And it does keep the white melamine from chipping.

   

   To bend around a corner, it is necessary to cut "Vees" into the tongue and remove portions. This will depend on how sharp the corner is.

   We use a small dab of thick CA gel from our handy FastCap CA kit. Follow this with a spray of accelerator and the bumper will hold in place after about 11 seconds holding time.

   We use the nylon filament strapping tape as edge clamps to hold the black edging in place while the glue sets. Apply a few inches on top surface and then pull over the edging and fasten a few inches on the underside. Using the CA glue might make this step unnecessary but better safe than sorry.

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