Different method for clamping sheaths on Jack Lites

[Harley]

OK, here is the method I use for clamping the sheaths of the Jack lites into place WITHOUT using proprietary clamps.

This method will not suit everyone, but will be time saving for the astute.

The reason I do it is because I never build one off of a cab, it's always at least two, most times four for any one build project. This means I don't have to have a lot of clamps ready with fiddly bits of wood and it frees up the build for me to carry on.

There are dangers with this method.

1) If you don't wrap the rectangles with food wrap beforehand, it's good night and good gardening.
2) Whilst the width cut must produce a tight fit, don't make it over-tight otherwise the food wrap will split..
3) When sliding the sheaths into place and ramming the block in, ENSURE the sheaths butt fully to the edge of the driver baffle.
4) It takes an effort to pull the rectangle blocks out, but they will come out. Do this AFTER the PL has set Hence the cord knotted through the holes

The beauty of this method is that when you come to build more Lites, you have a time saving clamp system. The downside is you spend a couple of more bucks on ply ( I use rubbish 1/2" )

It takes no longer to make those rectangles than it does to make the clamp blocks mentioned in the plans - you just have to be more accurate that's all.

[Jools4001]

Nice one Harley....

48 hours too late for me on the main sheaths, but I'll definitely be giving this a go on the minor ones.

[Hackomatic]

I just LOVE this kind of engineering prowess!

[LelandCrooks]

King of the jigs.

[Scott Brochu]

Well thought out.

[Drey Chennells]

Nice!

[Harley]

Thanks for the positive feedback guys, but if you're doing just one cab or new to this, best stick with what's in the plans.

HAVING SAID THAT THOUGH, I'd be interested if someone else tires this method and gives me some feedback.

Nice one Harley....

48 hours too late for me on the main sheaths, but I'll definitely be giving this a go on the minor ones.

Don't forget the food wrap over the 'clamp-plugs' otherwise you'll end up with a doubly thick baffle plate that you'll have to chisel some openings out of or preform some death defying stunts with your multi-tool

Bill! - I have saved the sketchups of these if you wish to have them

[Hackomatic]

Don't forget the food wrap over the 'clamp-plugs' otherwise you'll end up with a doubly thick baffle plate that you'll have to chisel some openings out of or preform some death defying stunts with your multi-tool

Perhaps if you were gonna make enough J-lites to justify the investment, making the rectangle out of something other than ply might be worth it. Nylon sheet comes to mind. 12x24x1/2" about $48. Aint nothin' sticking to that!

[CoronaOperator]

Perhaps if you were gonna make enough J-lites to justify the investment, making the rectangle out of something other than ply might be worth it. Nylon sheet comes to mind. 12x24x1/2" about $48. Aint nothin' sticking to that!

Good idea, a 1/2" white HDPE kitchen cutting board would do the trick for about $10

[Harley]

Good idea, a 1/2" white HDPE kitchen cutting board would do the trick for about $10

You need at least 1/2" thick. I found thinner can easily slip out of place.

[Grant Bunter]

You come up with some great ideas Harley!

[AntonZ]

Perhaps if you were gonna make enough J-lites to justify the investment, making the rectangle out of something other than ply might be worth it. Nylon sheet comes to mind. 12x24x1/2" about $48. Aint nothin' sticking to that!

Good idea, a 1/2" white HDPE kitchen cutting board would do the trick for about $10

Ikea springs to mind for things like that. If you need thicker, seeing as nothing sticks we can't glue them, but you could bolt two or three together.