DIY: making Bosch track clamps

Watch me iterate through a few designs of clamps for a Bosch track saw, for example the FSN 800 track.

The Bosch tracks have very small slits for clamps accepting clamps that are approx 12mm wide and about 1.75mm thick so not a lot to play with as the tracks are only about 5.1 thick excluding the track protrusion that the saw runs along.

One of the initial designs was to enlarge the hole at the end of the donor clamp and drill a second hole. This proved really difficult in the hardened steel bar. I found it easiest to make a small divot using a large diameter drill bit and then switching to a small drill bit and moving up in 0.5mm increments to the final hole size. using cutting oil helped, so too did reducing the drill speed.

The 3D printed extension was:

The 3D printed clamp rod bracket holder was:

[alanlloyd]

Love the angle grinder cut off jig, so simple, brilliant!

[continental_drift]

The hole in the piece of wood was a good idea.
Angle grinder on a piece of wood for horizontal control
Often I find people's techniques of doing instructive.

[TrevorDennis]

The first time I used my Bosch track saw guide rail it moved, despite the blurb sawing its weight and rubber insert would keep it steady. As much as I hate losing even the two clamps, the Bosch FSN KZW clamps are a crazy £66 on Amazon, so easily worth it. Plus I have full metal working facilities at my Menz Shed, so I know what my wee project for tomorrow is going to be (I'm a retired toolmaker). BTW I noticed there was perhaps a bit more resistance to sliding my saw on the track. Do you use wax to make the saw slide more easily? I am using the slightly bigger GKS 18V-68GC saw which weighs 4.3Kg so that might make a difference. Thanks for the idea.

[whirled_peas]

Hah that's a great use for those pants wee irwin quick clamps. I'll have to do this with mine. I suspect welding one of those t-track bolts to the clamp bar would work. Even epoxy/JB weld would do it I think.

[alexpetersheldon]

I think if I had access to a 3D printer I would have made a part that slides into the track and has a hole through it to bolt to the clamp. Although perhaps the plastic wouldn't have been strong enough when under tension

[Zogg]

I much prefer your finished clamp, the 1st one was so out of line it didn't really stand a chance. I'm glad you persisted and I live the 3D printed components! A 3D printer would be my dream at the that or an X or both lol

[lemech]

Good Job! What's the model number of the Ryobi workbench and where did you buy it? Thanks

[rickychatt]

Could have welded a washer on top and cut off the width