Frontline Clamps Review

[aarggh]

Disclaimer: My apologies in advance as this fairly comprehensive review (and slight comparison) might be a bit lengthy and is based purely on my opinion and experiences, which may not align with yours, or others views. In essence, I wanted to detail the many reasons I became such an immediate fan of Frontline Interlocking clamps, along with as many technical details as possible, so people can see exactly why these are so different to anything else in this market, and are well worth every cent.

Spending large amounts of hard earned cash can be daunting for anyone, especially if you aren't entirely sure what you buy will work as required or will potentially be a waste of money. I think we're all guilty of having bought tools thinking they'll be perfect for an intended purpose, only to find they didn't perform as intended, were difficult in some aspect or function, or just a damn PITA to use generally.

But every so often a product comes along that is just so unique, so well designed, and is just a joy to use. For me the first time I experienced that was when I bought my ELU flipsaw some 35 odd years ago. At the time it was utterly unique and was THE bee's knees of a contractor mitre/rip saw, and so well designed that close to 40 years later they still command a very good price second hand. Fein did it with the Multi Tool, an amazingly useful product when it hit the market, and now pretty much an essential tool for most people. Festool did it with their Domino, again an absolutely amazing tool improving upon dowelling jigs and biscuit joiners, producing a product so unique and with such high precision you'd display it on the mantel piece!

That's exactly how I felt when I first got my Frontline clamps, and it was further reinforced the first time I used them, any thoughts I'd had of "well that was a lot of money spent" went out the window, and I have never regretted them a single day since!

While these clamps seem expensive, and I hear comments to that effect in the forums, the value for money these clamps provide is just astounding. They are purpose built and borne out of a need of a (clearly very entrepreneurial) professional woodworker who ran a large cabinet making company for many years. So after looking at them, and especially after using them, it's quite obvious to see they are not only designed to perform, but are also clearly built to a standard, not down to a price. There's a number of very good reasons why you'll see these clamps used extensively in cabinetry and furniture making businesses, instead of other types or brands of clamps.

I can see numerous ways in which Con could have chosen to save on materials, manufacturing costs, increased limits, etc, but of course all at the expense of the high standard he set. Do the assemblies really need 10mm thick hardened steel plates? probably not, would one high quality spring instead of two do the job? maybe, does the aluminium profile really need all the edges chamfered when other brands simply square cut the ends of their clamps? not really, etc, etc. But these are the design touches that show the inventors pride in work and help set this product apart from all the other ones on the market, it's immediately apparent absolutely no corners were cut, and everything has been over engineered to guarantee maximum robustness, performance, quality, and longevity.

These are the clamps you buy once, and use for the rest of your life. Or if unfortunately circumstances change, resell them if necessary, as the resale value of these as with all really high quality products is very good, Festool resale type good!

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First Glance:

I'll go into more detail on each aspect of the clamps later, but at first glance It's really hard to appreciate just how large, rugged and well designed these clamps are from online pics or videos. Holding them up close however it becomes very apparent that every part has not only been beautifully machined, but also really well designed. It's not until you use them that you appreciate the level of thought and engineering that went into them. The rails measure 80mm high x 75mm wide, and are exceptionally well made and due to the profile, provide a level of rigidity that is astounding.

Con sells clamps in standard sizes of 900mm, 1200, and 1500mm (and longer ones used industrially mainly), in a standard height, and an extended height. The difference between the two is the height of the assemblies. My 1200mm clamp set is 1450mm long overall, and I actually get around 1230mm max clamping width, so it will easily accommodate standard 4' (Imperial) size panels. The handle is Chrome Vanadium steel, and makes winding the leadscrew an effortless task. The 1200mm clamp sets are each a touch under 13Kg, and with the substantial size of the rail profile, sit nice and firmly on whatever surface they're on.

Looking at the end on comparison pics, the left two clamps are both standard height sets, in low and high mode, the two on the right are extended height clamp sets, also in low and high mode. You can see how the assembly slides into the upper or lower channel to use the low or high mode. The solid locking pins (12mm x 85mm hardened steel) have a spring loaded ball bearing to retain them, and are easily popped in/out to change the clamping width or height as required.

You can also get nylon protective strips which makes cleaning up really easy. These strips are purpose designed for this profile, and are a very strong, and firm material, getting them onto the rails can be a tricky affair, but is made far easier by simply clamping one end of the rail down to a bench or table to allow you some leverage.

Great review by Stu's Shed (check out his channel!):
Episode 52 Frontline Interlocking Clamp | Stu's Shed

Another great review from Steve's Festool Shed (another great channel)
Part 1: Frontline Engineering Clamps Part 1 - YouTube
Part 2: Frontline Engineering clamps Part 2 - YouTube
Part 3: Frontline Clamps Part 3 - YouTube

Video from Too Guy republic (starring Con himself!):
Frontline Wood Clamp System - Flatten & Clamp in One Action - YouTube

Video from Con, the inventor of Frontline clamps (again starring Con!):
https://www.youtube.com/watch?v=xj7zvcdcYLo

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Plano / Frontline Comparison:

I don't want to turn this into a turf war or be too negative, and again this is purely based on my own opinions and experience with these clamps, so I won't dwell too much here, especially as I think the attached photos tell the story pretty well here! But what prompted me to finally ( I intended it for some years, Covid gave me the time!) write this review is in part because of queries/comments over the years regarding Frontline and other clamps, occasionally with references from people who have never seen a Frontline clamp in the wild, let alone held one, make direct comparisons to Plano clamps, homemade bar clamps, and even the Veritas style bar clamp kits, often asserting "no difference bar cost"!

Comparing any of these to a Frontline clamp is like comparing a dowelling jig to a Festool Domino, there just is no comparison and they are NOT like for like!

Out of the very small amount of alternate panel style clamps on the market, Plano is pretty much the only other real contender to a Frontline style clamp, but in my opinion, after having bought and used them, the build quality, performance, and usability simply do not compare to Frontline clamps. As mentioned earlier, in use I found them far too flimsy and finicky, with sub-par results, and I absolutely hated the fiddly mechanisms. For many I'm sure they have a welcome place and that's great, but not in my shed.

At the very least though no matter how popular they may be for some, I'm sure most people would agree they are just ridiculously priced given the performance, parts design and build quality, I know I certainly felt more than a bit ripped off after using them.

The timber seen clamped has simply been placed and clamped, no mallet use or board alignment performed on either clamp set. The thickness did vary slightly with a few boards, 90 x 45 Pine framing being what it is. The Plano clamp set shown (900mm) weighs 3.76Kg total, with a third of the weight (1.225Kg) in the steel mechanisms, so calculating the weight of the aluminium rails (2.535Kg) will make a 1200mm set around 4.45Kg all up including the mechanisms.

The Frontline 1200mm clamp sets weigh in at 12.75Kg for the Standard Height (older design) clamps, and 12.8Kg for the Extended Height (newer design) clamps. The newer assemblies have reduced the weight quite a bit, whilst remaining as strong, if not even stronger due to the enhanced shape.

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Minimum and Maximum Clamping Ranges for the Standard and Extended Height Clamps:

The attached pics show one of each of the Standard Height clamps and Extended Height clamps in a Low and High height mode, so 8 pics total. To change the height to be clamped simply involves sliding the metal End Stop and Thrust Bearing assemblies into the upper or lower channel in the rails, suitable for the thickness you want to clamp. The spring loaded assembly stays put.

I've also included pics of two variants showing the pin engagement on the assemblies, as I tend to push the clamping range to the max and have it hanging on by a whisker, while still maintaining a safe clamping setup so I can squeeze that extra bit of thickness out. As the clamps are forced in opposite directions pulling them against the locking pins, and my clamps in use are invariably out of the way either standing against a wall, or laying on a frame or table, consequently I've never been concerned about the prospect of them coming apart (never had one come apart yet) if it was hit by something sufficiently big/heavy enough. If you were really concerned about running too close to the wind though, you could probably shave 1.5-2mm off the max height to give a larger margin of safety, or whatever you're comfortable with really. Again, it's a 45 degree slot on the assembly that engages the locking pin at each end, so the amount of force holding them in place is quite large.

The ranges as measured on my own clamps:

- Standard Height Clamp Set in Low Height Mode had a range of 10mm - 55mm
- Standard Height Clamp Set in High Height Mode had a range of 33mm - 75mm
- Extended Height Clamp Set in Low Height Mode had a range of 34mm - 80mm
- Extended Height Clamp Set in High Height Mode had a range of 52mm - 105mm

It's important to note though, if you're using the Nylon Protective Strips, you'll need to deduct exactly 4mm total off each of the Min and Max ranges. The strips add exactly 2mm to each clamp.

If you find the Min clamping range is too high for the material you want to clamp, you can simply use a packing strip of MDF or whatever, ideally wrapped in Gladwrap or foil (to not stick) under the timber to be clamped, this will work perfectly fine, and even allow you to successfully do materials as thin as veneers with ease (obviously with a board top/bottom for even all over pressure).

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Sash Clamp Mode:

As seen by the attached pic, each clamp set can also operate in a sash clamp mode using the end assembly from the bottom clamp with the top rail that the thrust bearing assembly is fitted to.

This is incredibly useful for quick and simple glue ups, and as the rail profile is so wide, it sits beautifully flat, unlike the precarious nature of traditional sash clamps that always seem to want to flip on their side. Another thing to note is the shape of the rail profile itself, this is no cheap tube or square walled rail like most cheap clamps are, these are maximised for rigidity, so that even in sash clamp mode, will strongly resist any tendency to bow, unlike pipe/sash clamps which seem to have a mind of their own in use!

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Thrust Bearing Assembly:

Out of all the well machined and designed components with these clamps, nothing screams quality and thoughtful engineering to me as much as these bearing assemblies, just feast your eyes on all those beautifully machined parts! A huge chunk of machined aluminium with a very large, good quality(German I believe from memory) thrust bearing, so no matter how much it's tightened, you get no lift or shift of material whatsoever! Pretty amazing really, I certainly have never had clamps that thought of such a simple and obvious, but very crucial and helpful detail like that. And I don't think I've even seen others designed like that from my recollection.

I know from my CNC machine and spindles that good quality thrust bearings are quite expensive, so the manufacturing and material costs certainly couldn't be cheap for this assembly!

As you can seen by the attached pic, this assembly is a very sizable and impressive bit of kit, and can achieve an absolutely astounding amount of force when clamping. In fact it is pretty easy with not much effort at all to over tighten the clamp and end up really crushing the timber, which is why you would always want to have an offcut of timber between the panel to be glued and the clamp ends.

The leadscrew, 3/4" or M19 thread by the look, allows you to apply large amounts of force gradually and very smoothly, instead of the clunky, aggressive pitch on a lot of other clamps, and it can be moved into a lower or upper position on the assembly depending on how you're using the clamps, and the size of the timber. Generally though, unless you are using the clamp in sash clamp mode, you would probably never move it from the default position. Or maybe that's me just being lazy.

The leadscrew as mentioned prior does also allow a very generous ~112mm travel, which you may not think matters that much, but it is extremely useful in practice to not be bound by a small amount of travel with a clamp.

I've been using my set for around 15 years, and must admit I probably tend to apply too much of a death grip, but my set has no detectable wear or issues of any kind, despite the staggering amount of use over the years. I have no doubt they'll well and truly outlast me!

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Spring Assembly:

The two massive (1" diameter!) springs on these assemblies are what helps apply the clamping pressure across the face of the material, forcing the top and bottom clamps to slide in opposite directions using a simple yet absolutely ingenious, angled inter-locking mechanism, this exerts a tremendous amount of pressure on the faces which first aligns the boards dead flat, before any side pressure has even been applied! This is the meaning of a true 4-way clamp. Once the sides have been clamped, the whole assembly is dead flat, and straight, and the clamps can exert something along the lines of 4 ton pressure, so you can really apply a massive amount of force!

The clamps come supplied with a piece of polycarbonate that stops glue from dripping on the assemblies.

If I can work out a way of measuring the actual force applied I'll do that down the track, but in use I've found the force is enough to flatten quite thick (~45mm), and somewhat twisted boards (as can be seen by the twisted 90 x 45 Pine framing in the pic comparing the Plano to the Frontline).

Obviously if they are overly twisted/cupped, etc, and depending on what type of timber it is, it might well be that nothing short of magic will automatically flatten them so they might need a few hits with a mallet. Boards that are quite bowed but glued together along the face, not the edges, will usually work out just fine. I've made a few work tops over the years for mates out of quite bowed and lightly twisted 90 x 45 Pine framing, and they have held up quite well I've been told despite the abuse given to them.

Thin boards (~8mm-13mm or so) no matter how bowed/twisted (within reason) seem to come together and stay that way pretty fine I've found, thicker boards (~19mm-30mm or so) if not too bowed/twisted generally work out just fine. Going thicker than that with ideally minimal twisting/bowing also tends to work out fine usually. Again, common sense applies, if you're gluing up boards that are that twisted and especially if it's a dense hardwood, you'll likely find that in use the timber will naturally (and sometimes quickly) fracture, or work the joins apart to find equilibrium anyway.

It's important to note, in order to let the springs do their job in flattening the panel faces before side pressure is applied, you need to leave some space, 2-3 inches is good, between the boards being glued up and the thrust bearing assembly, so the springs have room to extend, thus putting pressure on the clamp rails to ensure flatness of the panel. Again, very thoughtful design has ensured you have around 112mm travel, leaving plenty of room to spare! No bruised knuckles when clamping up!

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Design Improvements/Evolution:

It looks like Con hasn't been standing still with his original clamps, and has been refining and improving certain aspects of them, although there's not really much that can be improved upon, he has managed to reduce the weight of the hardened steel assemblies with a new, and even stronger design. I won't detail all the differences here, but as an example, the (older design) Standard Height Spring Assembly at 270mm long x 142mm high weighs in at 1.675Kg while the (newer design) Extended Height Spring Assembly at 230mm long x 166mm high weighs in at only a fraction more at 1.72Kg, whilst further increasing the strength and rigidity of this component. Without the improvements to weight reduction, the Extended Height set I would have estimated to come in around the 14.5Kg mark all up based on the existing older design components in my set.

[aldav]

Thanks for that very comprehensive review, aarggh. Anybody who's ever had any doubt about the quality of Frontline clamps should now have had them fully expunged. They're certainly built like a brick s!@#house. If you need some clamps to make a panel out of any old bent, warped and twisted timber these would be your go to clamps. Personally I prefer to make panels using jointed and thicknessed material. About the only negative with the Frontlines as opposed to the Plano style clamps is the amount of space you need to accommodate them, the Frontlines designed to be used horizontally compared to the Plano vertical orientation - that alone would be a deal breaker for me.

I certainly agree with you regarding the price of the Plano clamps, you can at times however buy an identical example for less than half the cost of genuine Plano clamps.

[aarggh]

They certainly are very sizeable, but I don't really have a trouble with room despite my quite small workspace.

I generally do smaller stuff more than bigger stuff, but even when doing a door or large panel, I usually line them up against a wall at a slight angle and clamp up that way, pretty much exactly the same as what Plano owners do currently. Most often though I'm doing small stuff like the attached pic where once I've clamped up the timber on the bench, I can then just stick the panel on it's end anywhere out of the way and move onto the next one.

This is where the sash clamp mode and the width of the rail is super useful, especially seeing as Titebond has such a small working time, I can glue up one block at a time easily and quickly without the glue setting the timber in the wrong position.

I used to hate doing this with traditional sash clamps, it was always a messy and awkward affair.

[aldav]

Yep, they're pretty versatile alright. I know what you mean about sash clamps.

[Albert]

Thanks for the comprehensive review, I have 6 of these bad boys in my workshop. plano clamps come no where near them.

I wanted to buy them in 1.8m or even 2.4m lengths but no, they only come in 1.2m... yes there are extensions you can get from Frontline but its a PITA to setup

[aarggh]

That's weird Albert, maybe my memory served me wrong about the longer lengths, or that was something done at the time I bought mine as it was many years ago, as I'm sure that was the case. I might reach out to Con and see if he'll confirm.

[Albert]

That's weird Albert, maybe my memory served me wrong about the longer lengths, or that was something done at the time I bought mine as it was many years ago, as I'm sure that was the case. I might reach out to Con and see if he'll confirm.

Thanks, I bought my first 4 maybe 10 years ago, and another 2 about 5 years ago. I recently checked with the agent in NZ. it seems the sale on these are low and hence the agent only brings in 1.2m long..

[BEM]

I bought three Frontline clamps yesterday after watching Steve's YouTube videos. That was a REAL lucky break for me. I was planning on buying the Plano clamps. While I was at the factory chatting with Con, he showed me this review. Thanks aarggh for an informative and entertaining read. I really appreciate the detail.


aldav. Con also sells a trolley stand set, so that you can move them around. They will still be horizontal but you can move them out of the way.

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