Create Flat Glue Ups with This Step-by-Step Tutorial on Assembling and Using 4-Way Panel Clamps
When creating table tops or cutting boards with edge-joined boards, it’s crucial to ensure that the board joints are tight and perfectly flat for professional-looking results. These amazing 4-way panel clamps are essential for such projects and make the gluing process a breeze. However, some of the panel clamps come in a kit that needs to be assembled manually. This tutorial on how to assemble 4-way panel clamps will help you get started on your project quickly and easily!
Why Use 4 way Panel Clamps?
When using regular claps, it’s hard to get even pressure from the sides, ends and top/bottom. Panel clamps take all of the work out of that and help prevent bowing, racking and buckling that is common with panel glue ups. The best part about the panel clamp kits is that they can be made in whatever length you choose so you’re not limited to certain widths for table tops. The most common lengths are 24″, 36″ or 48″. I made my first set 16″ long so that I could use the clamps for hardwood cutting boards (available in my store).
Plus, this particular kit will allow me to make glue ups up to 6″ thick so I can use them to make hardwood yoga blocks, as well!
Let’s get started!
Materials:
- 4 way Panel Clamp Kit (<– affiliate link!)
- 4 – 2×2 lumber at the length you’d like your finished clamps to be
- Tyvek tape (<– affiliate link) or tape for silicone molds
- Drill
- Tape Measure
The kit linked above contains everything you need to create a set of two panel clamps. I recommend using 2×2 hardwood boards because they are usually straighter than pine but if pine is all you can get, it is perfectly fine!
It is also recommended to use one clamp every 12″ to 18″ of your glue up so if you have a long piece, more than two may be needed. The kits are sold as single clamps (<– affiliate link!), too.
Step One
Start by laying out your boards to make sure they are the same length. I clamped mine together, then trimmed the edge so they were alike.
Step Two
While the boards are still clamped together (if you did that), draw a line across all four boards 2″ in from one edge.
Step Three
Apply the Tyvek tape (or other non-stick tape) to the side of the boards that will face your project once clamped. This will keep glue from sticking to the clamps during glue ups.
Step Four
Start securing the notched plastic bars to the 2x2s. One set of the bars will be secured so they are flush with the edge, and the other set will be secured along the pencil line drawn in the previous step.
Pro tip: Pre-drill the holes! The screws are hefty and a pre-drilled hole is very helpful before driving the screws. I clamped the bar to the board then drilled through the screw holes for accurate positioning.
Your notched bars maybe spaced farther apart than mine – it depends on the length of the board!
Now, let’s assemble the clamps!
Also included in the kit are plastic pads that attach to the rotating clamp handle as well as the stationary spring hinge. Secure these pads using the screws provided.
Open the stationary springs and place one of the boards in it, notched piece down on top of the bar of the spring, then position the second board on top with the bar from the other end of the clamp resting in one of the notches. Make sure that if the bottom bar is in the first notch, the top bar is also in the first notch of the corresponding board. See the photo below for reference. Note that the end of the boards with the 2″ space goes in the stationary spring.
Now, do the same thing with the springs with the rotating clamp handle, positioning the bars of the spring in corresponding notches. Once your project is placed inside the clamps, the pads on the stationary spring and the rotating handle will press against the glued boards. As the handle is turned, the pressure will increase creating super tight joints and a flat assembly!
So, to get your project between the clamps, lift both of the top bars on the stationary spring and the handle spring and slide it back. Position your boards as you’d like, however you want to apply glue. Then when you’re ready, replace the top board under the springs (making sure the pads on the springs contact the first and last boards) then turn the handle until glue comes up through the joints.
As a side note, the glue can be wiped away from the assembly while wet to make finishing easier. I’m lazy and just run it through the planer when the glue dries.
Have questions about the tutorial on assembling 4 way panel clamps? Leave a comment below!
