How to Make Simple Sheet Metal Vise Jaw Covers

Beginner Sheet Metal Project 2

Intro

Vise jaw covers are useful items to have lying around any shop. Making a pair of simple covers out of sheet metal also provides a great, simple, quick introduction in my classes to using a sheet metal brake to bend metal. Unlike making something like a set of dog tags where no bending of metal is needed, most sheet metal projects will need to be formed to the final version in some way. The most common way that forming operation happens is with the brake.

This is another quick project I have my students complete at the beginning of my class. After completing this vise jaw cover project and the dog tag project, my students have all the basic skills to start doing some more advanced projects, like the sheet metal box.

With that short introduction let's get into the project!

Tools and Materials

Tools

Ruler
Scratch Awl
Number/Letter Stamp Set (Optional)
Hammer
File
Brake

Materials

Sheet metal (I used 19 gauge)
Sandpaper (optional)
Clear Coat Spray Paint (optional)
Layout Fluid (optional)

Plans

My students always use a set of plans, even when working on simple projects.

I convey to my students that plans allow them to let your brain focus on just one thing at a time. Instead of trying to remember all the measurements, operations, and safety procedures all at the same time as they try to finish a project, their plans can be their memory for the measurements and operations so they can work more safely in the shop. Plans are great! As I always tell my students, if you are not already in the habit of using them, start now.

These covers are pretty simple to make. To start you need to take down the measurements of your vise and make some decisions on your design based on your own preferences. Use a ruler, tape measure, or (if you’re partial to them), dial calipers to get the information you need to add to the plans for your covers.

I've included this sketched drawing I use to use in my shop classes as an example if you would like to use it.

I've since moved onto giving my students this hopefully more accurate technical drawing to use during this project.

I have my students stamp their name and class period into the top of their covers so that they can leave them in the classroom and use them throughout the year. I'm not showing the stamping step in this post but if you would like to know how to imprint something onto your covers you can see that process here.

The order of operations for this step are as follows:

Measure and record the width, height and depth of your vise jaws.
Create a plan using your vise jaw measurements.

Cut to size

With the measurements of the vise recorded on the plans, I have my students move onto cutting their sheet metal to size. This is another great scrap metal project, as the amount of metal needed is so little. I always have a bunch of strips of scrap sheet metal from various class projects, so that is what I mostly have my students use for these covers.

To cut your sheet metal down, a simple set of compound shears (tin snips) work great.

If you and your students have access to a foot shear to make this cut that is what I recommend you use. The foot shear is what I have my students use to cut their metal because it will leave less jagged edges than when you use compound shears. Less jagged edges equals less clean up work later, so a foot shear or similar shearing tool is not needed but it is nice if you have access to one.

I have sprayed my metal with blue layout fluid to make it easier to see the layout marks in my pictures and the video. For simple projects like this, layout fluid is not really needed. You should be able to see the lines on your metal without it and the layout is incredibly simple.

The order of operations for this step are as follows:

Measure and mark the needed height on your metal.
Cut your metal to the needed height
Measure out the length needed to cover one vise jaw.
Cut metal to length with compound shears (tin snips).
Repeat steps to create your second cover

Layout

The finished covers should stay on the vise and not fall off. They should also not have a large amount of excess material hanging over the sides or off the bottom of the jaw.

Use the measurements from your plans to mark the needed bend line on your sheet metal.

In our shop the jaws on our vises are ½ thick. I could use ½ inch measurement for my bend line but usually adding a little extra material to the top part of your covers can help them stay in place better.

Adding an extra 1/8 to 1/4 inch to the top portion usually does the trick if needed.

The order of operations for this step are as follows:

Measure and mark the distance for your bend line.
Use your scratch awl to mark your bend line onto your metal.
Repeat the steps for your other piece of metal.

Round Sharp Corners

I have my students round off the sharp corners of their covers before bending.

Filing down the corners of these isn't necessary but more often than not I recommend completing this process. The less pokey, sharp bits that you have around your work area, the less chance you have of running into those dangerous bits and hurting yourself.

The order of operations for this step are as follows

Clamp your metal into the vise with a corner slightly sticking out.
Run your file across your metal at a slight angle away from you.
Continue to run your file across your metal, working the sharp corner into a rounded corner.
Repeat steps until all your corners are rounded.

bend

The goal is to bend each of the covers to 90 degrees using a sheet metal brake. The most important part of this step is to make sure you clamp the teeth/fingers of your brake right on your bend line. If you clamp you metal into the brake at an angle your covers may not stay on your vise jaws.

The order of operations for this step are as follows:

Use your clamping bar handle to lift the teeth of your brake.
Slide your metal piece underneath the teeth and line your marked line up with the edge of the teeth.
Lower the clamping bar handle down to clamp your metal into place.
Use your bending leaf handles to slowly fold your metal to 90 degrees
Return your bending leaf to neutral position and lift up your teeth to remove your bent meal.
Repeat steps to bend your other metal piece.

Project Complete

Take the finished covers over to your vise and try them out. Now your students can use the full strength of the vise without fear of leaving knurl marks all over their projects.

This is a great, quick little project that I use to teach my students how to use a couple of new tools in our shop.

If you feel the need, you can coat these sheet metal covers in some paint or clear coat so they won't rust. Just be sure if you do paint them, that you use sandpaper or some other abrasive to clean up and prepare your metal before painting if needed.

If you looking for another good beginning project, and you haven't checked it out yet, try out these SHEET METAL DOG TAGS.

If you do a project like this or use this version in your class let me know at

shopclassbuilds@gmail.com

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