Transforming A Mediocre Table Saw Into A Mastery Marvel

If you're struggling with a table saw that's not up to scratch, don't despair! With a few modifications, you can turn that frustrating piece of equipment into a much more capable tool. This guide will take you through the steps to improve your table saw's performance and make your woodworking projects more enjoyable and efficient. From adjusting the fence and riving knife to adding castors and dust collection, you'll be surprised at what a difference these changes can make. So, whether you're a hobbyist or a professional, read on to learn how to get the most out of your table saw.

Create a new fence using 50mm aluminium angle running in a channel

Creating a new fence using 50mm aluminium angle running in a channel is a great way to improve the functionality of a table saw. This modification is especially useful if you are working with a small workshop space, as it can help you maximise your workspace.

To create this new fence, you will need to use oak for the fence itself and melamine for the facing. The aluminium angle will serve as a guide, ensuring straight and accurate cuts. Start by cutting your oak to size, making sure it is straight and true. You will also need to cut the melamine to size and attach it to the oak securely. This can be done with a strong adhesive or by screwing it in place.

Once your fence is assembled, you will need to create the channel for the aluminium angle to run in. This can be done by fixing channels onto the saw body, ensuring they are straight and level. You can then insert the aluminium angle into the channel, creating a smooth and precise guide for your fence.

It is important to note that you may need to adjust the height or position of your guard and riving knife to accommodate your new fence. Test the setup thoroughly before use to ensure it is secure and functioning correctly.

With these modifications, you can significantly improve the performance and accuracy of your table saw, even if it started as a "crappy" one.

Reposition the guard on an extendible arm

Repositioning the guard on an extendible arm is a great way to improve the functionality of your table saw. This modification allows for a greater range of motion and adjustability, ensuring that the guard can be positioned exactly where it needs to be during operation.

To achieve this, you will need to make some changes to the existing guard assembly. Firstly, cut off the existing guard holder using a grinder and smooth it into a nice curve. This will create a more ergonomic design and provide a better base for the extendible arm.

Next, source an extendible arm that can be attached to the modified guard holder. This arm should be able to extend and retract smoothly, allowing you to position the guard at various distances from the blade. You may need to fabricate a custom solution or adapt a ready-made extendible arm to fit your specific table saw model.

Once the extendible arm is attached, you will have much greater flexibility in using your table saw. You will be able to adjust the guard to accommodate different types of cuts and workpieces, ensuring that your hands and body are always protected from the blade.

Remember to test the repositioned guard thoroughly before using the table saw for any projects. Ensure that the guard does not obstruct your view of the blade and that it can be securely locked into place during operation. With this modification, you can significantly improve the safety and functionality of your crappy table saw.

Add a dust collection bucket

Adding a dust collection bucket to your table saw is a great way to improve its dust collection capabilities and keep your workspace clean. Here are the steps you can follow to achieve this:

Step 1: Measure and Cut the Dust Hood

If your table saw has an opening at the bottom, you can fill this space with a dust collection hood. Start by measuring the size of the opening and then trim a plastic dust hood to fit securely in place. This will ensure that dust falls directly into the collection bucket.

Step 2: Attach the Elbow Joint

Attach an articulating elbow joint to the dust hood using sheet metal screws. Adjust the elbow so that it points downward at a 45-degree angle. This will direct the dust down into the bucket.

Step 3: Measure and Cut an Exit Hole

With the elbow attached, place the hood in the bottom opening of the table saw. Measure where the elbow intersects the back panel and drill a locating hole. Cut out a hole, approximately 5 inches in diameter, to allow the dust to exit.

Step 4: Measure and Cut the Exit Duct

Assemble a section of straight duct and insert it through the exit hole. Mark the length of this piece so that it fits snugly, and then cut it to size. This duct will direct the dust from the table saw into the collection bucket.

Step 5: Assemble and Secure the Duct

Seal the seams of the duct with duct tape and crimp the end if necessary. Attach another articulating elbow to the duct, and tape and screw the joints together. This will allow for easy adjustment and movement.

Step 6: Connect the Dust Adapter

Thread the exit duct through the exit hole and insert the dust hood into the opening at the bottom of the saw. Adjust the final elbow to point towards your dust collection bucket. Attach a dust adapter that fits your bucket or vacuum.

Step 7: Seal Gaps with Tape

To ensure optimal dust collection, seal any remaining gaps around the dust hood with duct tape. This will minimise air loss and prevent dust from escaping into the cabinet or your workspace.

By following these steps, you can effectively add a dust collection bucket to your table saw, improving its dust collection capabilities and keeping your work area clean and safe.

Make a sliding adjustable 5-position guard

Table saws are powerful tools that can be used to make quick, precise cuts. However, they can also be dangerous if not handled properly. To ensure safety and efficiency when using a table saw, it is important to have a good blade guard in place.

A table saw splitter is a safety device that helps to prevent kickback, which is when the workpiece is thrown back towards the operator. It also keeps the kerf from closing behind the blade, reducing the risk of the workpiece binding the blade.

A blade guard provides a measure of protection by marking and securing a safe area around the blade. It also helps to prevent objects from dropping onto the running blade and keeps sawdust from flying into your face.

My Solution

I designed and built my own table saw splitter and blade guard after being unsatisfied with the options available on the market. My splitter is made from a chunk of aluminum construction rule, which I cut to size and shaped to allow clearance for the blade. I also added a simple blade guard to prevent objects from dropping onto the blade.

Adjusting the Splitter

The splitter can be adjusted to align with the blade by loosening the splitter bolt and moving it in or out. On my Powermatic 66 saw, the splitter bolt is threaded into a larger bolt that can be adjusted, while on my Grizzly 1023S saw, I used shims to achieve the correct alignment.

By following these steps and making some adjustments based on your specific saw, you can create a custom table saw splitter and blade guard that provide both safety and functionality.

Add a removable router table

Adding a removable router table to your table saw is a great way to save space, time, and money. Here's a step-by-step guide on how to do it:

Step 1: Planning and Materials

Before you begin, it's important to measure your table saw and plan the dimensions of your router table accordingly. You'll need a full-size table saw with an extension, and a mini router table intended to be mounted on a workbench. In addition to the table saw, you'll need tools like a cordless drill, a hand saw, a jigsaw, measuring tape, wood glue, screws, clamps, and sandpaper.

Step 2: Measure and Cut the Frame

Measure the size of the hole in the table extension and the size of the table itself. Cut the pieces for the frame according to these measurements, ensuring that the width is critical and the frame fits snugly. Cut a rebate at the end of each piece so that the frame is at the desired height.

Step 3: Assemble the Frame

Glue and screw the frame pieces together. Place the frame on the table and mark the locations of the bolt holes for attaching it to the table. Drill these holes and elongate them for height adjustment. You may need to adjust the size of the frame to fit your table saw perfectly.

Step 4: Install the Ledges

Install ledges inside the table frame to support the bottom plywood layer. Use a scrap piece of wood as a gauge to ensure the ledges are at the correct depth. The ledges should be positioned accurately using a scrap depth gauge.

Step 5: Fit the Frame

Place the frame into position on the table saw. The middle and top layers will rest on top of the frame, so set the frame about 5/16" lower than the cast-iron saw surface. Mark the bolt hole locations and drill the holes. You may need to adjust the size of the holes for fine-tuning.

Step 6: Create the Bottom Layer

Measure the inside dimensions of the frame and cut a piece of plywood to fit. This layer will block access to the bolt holes, so mark and cut away small areas to provide clearance for a wrench. Cut a large access hole for the shop vacuum dust port and a smaller hole for the router's collet.

Step 7: Middle and Top Layers

Cut the middle MDF layer and top laminate layer oversized, adding an inch to the length and width of the frame. This will result in a 1/2" overhang on all sides. Glue the laminate work surface onto the MDF layer using contact cement and a roller.

Step 8: Assemble the Layers

Glue the top layers onto the plywood bottom layer, ensuring that the bit opening in the top layer is concentric with the router bit. Clamp the layers together and remove the router. Mark the position and glue the top layer to the plywood layer, being careful not to get glue in the vacuum chamber area.

Step 9: Trim and Complete the Table

Trim the laminate and MDF layers even with the outside edges of the router table frame using a piloted flush-trim bit. File or sand the edges smooth. Decide on the placement of the router, considering access to the on/off switch and the motor clamping mechanism. Drill holes for the router mounting screws, ensuring they don't go through the internal chamber.

Step 10: Attach the Table to the Saw

Bolt the completed router table to the table saw, ensuring it is level and well-aligned. You may need to adjust the bolt holes in the frame to get the router table flush with the saw table. With that, your removable router table is ready to use!

Frequently asked questions