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Cole-jaw extenders #2: Making the extender segments

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Blog entry by BuckeyeDennis posted 04-13-2021 09:54 PM 568 reads 0 times favorited 2 comments Add to Favorites Watch
« Part 1: Fixturing an out-of-round bowl Part 2 of Cole-jaw extenders series no next part

These jaw extenders are so easy to make that they hardly need any instructions. I’ll let the pictures do most of the talking.

Cut a square piece of plywood to the desired extension-jaw diameter. This will be the diameter when the jaws are closed. Lay out centerlines, diagonals, and the OD.

With the jaws fully closed, clamp the chuck and cole-jaw assembly to the workpiece, aligned as shown. Transfer the jaw-extender mounting holes to the workpiece using a transfer punch.

Now finish the layout (which I should have done originally). The corners have to be notched out as shown, to leave clearance for the T-handle of the chuck wrench. The inner circle is the OD of the cole jaws.

Route WoodAnchor fixturing slots along both centerlines.

Trim off the waste at the bandsaw, cutting outside of the lines.

Separate the jaw-extender segments along the diagonal layout lines. This quick-and-dirty WoodAnchor small-parts sled (constructed of scrap plywood) made that operation very easy.

Sand each jaw-extender segment to the layout lines (I used a disc sander for this), and drill the mounting holes.

Countersink the holes for the 8 mm flat-head mounting screws, and they’re ready to use!

-- Dennis 'We are all faced with a series of great opportunities, brilliantly disguised as impossible situations.' Charles Swindoll



2 comments so far

View James E McIntyre's profile

James E McIntyre

1267 posts in 2373 days


#1 posted 04-14-2021 05:33 PM

Fine work and photos. It would be nice if you could add some photos of it in action.

-- James E McIntyre

View BuckeyeDennis's profile

BuckeyeDennis

106 posts in 780 days


#2 posted 04-14-2021 06:02 PM

Thank you, James. I’ll add another installment later with some action photos, and hopefully a bit of decorative off-center turning on the bottom of the bowl. Wish me luck with that!

-- Dennis 'We are all faced with a series of great opportunities, brilliantly disguised as impossible situations.' Charles Swindoll

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