Extended Support Arms for Workstation

Instructions

Make two end pieces. Start with the 1/8" bit and helix the 1/4" hole all the way through the wood. Switch to the 1/4" bit for the rest. Helix the 8mm hole to a depth of 10mm. Pocket the inner hole (mortise) to a depth of 1/4". Finish by cutting the outside all the way through. Three .25" passes should do it, with the final pass a finishing pass. Make two support pieces. Three .25" passes should do it, with the final pass a finishing pass. Note that one end has rounded corners and the other does not. Make a tenon out of the non-radiused ends of the support pieces using the tenon file. Jig up the support with a spoil board and cut to a depth of 1/4". You don't have to go all the way around because the sides are already the correct width and height. All you need to do is radius the corners. Add some wood glue to the mortise hole and insert the tenon end of the support. Clamp together and let dry 24 hours. Position the T-Track so the end is just shy of the outer (radiused) end of the support and centered side-to-side. Mark the screw holes. Drill a pilot hole then attach the T-Track. Repeat for the second support. Insert the dowel pin the lower hole on the end piece and tap home. You can glue if you like but the friction fit is good. Attach the finished supports to the workstation as you would the supplied supports, using the cam clamps (adjust to get a good tight fit). Now you have lots of room to attach the support bar. You might have to adjust the bolts on the support bar to tightly grip the T-Track. I was able to get it so the adjustment worked with the T-Track and supplied supports. The clamps as supplied (link below) have a really long bolt so I replaced them with 1.5" bolt from the hardware store. A 2" bolt will also work. Insert the bolt through the upper hole and attach the clamps (see picture). Here are links to the hardware: Dowel Pins: https://amzn.to/3zN9426 Cam clamps: https://amzn.to/3zM30Hi T-Track: https://amzn.to/3zLZg8u