Long-Reach Clamps: Make Your Own Bar Clamp Extensions
There's nothing more frustrating than getting ready for a glue-up and discovering your clamps are just a little too short.
I ran into this problem while gluing hardwood edging around a large tabletop. My aluminum bar clamps worked fine for most projects, but they simply weren't long enough to reach across the table.
Rather than spend money on extra-long clamps that I'd only use occasionally, I decided to make a set of shop-built bar clamp extensions.
The solution uses a hardwood extension bar, a notched aluminum strip, and a couple of bolts. Best of all, the extensions can be installed whenever I need the extra reach.
Make a Hardwood Extension for the Clamp Bar
The first step is to cut a long strip of hardwood to match the size and shape of your existing clamp bar.
I used hard maple for its strength and durability.
The fit is important because the adjustable rear jaw needs to slide along the extension just as it does on the original clamp bar.
Take your time sizing the hardwood strip so the jaw moves freely without excessive play.
Add a Notched Aluminum Strip
The next step is to create a way for the adjustable clamp jaw to lock in place.
To do this, cut a groove along the length of the hardwood extension using the table saw.
The groove holds an aluminum strip with a series of evenly spaced notches.
These notches serve the same purpose as the locking positions on the original clamp bar, allowing the rear jaw to engage at different locations.
The aluminum strip can be notched using a table saw equipped with a blade specifically rated for cutting nonferrous metals, provided the saw and blade manufacturers permit the operation. Secure the material appropriately and follow the recommended cutting procedure.
Connect the Extension to the Bar Clamp
With the hardwood extension prepared, the final step is to attach it to the existing clamp.
As shown in the drawing, cut a tenon on one end of the extension to fit inside the hollow aluminum clamp bar.
The tenon creates a connection between the original bar and the extension.
Next, drill matching holes through the end of the clamp bar and the extension tenon.
Bolts and locknuts secure the two pieces together.
Because the connection is removable, you can install the extension when you need extra reach and take it off for everyday clamping.
More Clamping Reach Without Buying Longer Clamps
These homemade bar clamp extensions are especially useful for occasional oversized glue-ups, such as attaching edging to large tabletops.
Instead of keeping a collection of extra-long clamps that rarely get used, you can make better use of the clamps already hanging on your shop wall.
Just keep in mind that an extended clamp may not have the same strength or rigidity as the original bar. The added joint and longer reach can increase flexing, so use moderate clamping pressure and inspect the connection before each use.
For occasional large woodworking projects, though, these removable extensions can be a practical and inexpensive addition to your clamping setup.
The Essential Clamps Every Woodworker Needs
Shop-made clamp extensions are a great way to get more from the clamps you already own. But having the right types of clamps in your workshop can make every glue-up and assembly easier.
In The Essential Clamps Every Woodworker Needs: A Beginner's Guide to Woodworking Clamps, Bryan walks you through the must-have clamps for any woodworking shop. Learn which clamps are worth buying first, when to use each type, and how to build a versatile collection that can handle everything from small projects to large furniture assemblies.
Whether you're just starting out or looking to expand your clamp collection, this video guide will help you choose the right tools for the job.
WATCH THE ESSENTIAL CLAMPS GUIDE → Build a Better Clamp Collection for Your Workshop
