Crafting A Custom Table Saw Blade Sharpener: A Diy Guide

Table saw blades are bound to get blunt after a few uses, but that doesn't mean you need to get rid of them. You can sharpen them to make them as good as new. There are several ways to sharpen a table saw blade, including using a diamond saw blade, a jig, or a hand sharpening method with sandpaper. However, it's important to note that sharpening blades can be dangerous and requires precision, so it may be worth considering professional sharpening services or investing in higher-quality blades that stay sharp longer.

Safety equipment

When sharpening a table saw blade, safety should be a top priority. Here is a list of safety equipment you should use to protect yourself from injury:

Safety Goggles

Safety goggles are essential to protect your eyes from small particles and debris that may be generated during the sharpening process. They will prevent any foreign objects from entering your eye area and causing irritation or injury.

Gloves

A good pair of gloves will protect your hands from cuts and bruises. It is important to choose gloves that are cut-resistant and provide a secure grip to reduce the risk of slipping during the sharpening process.

Ear Protection

The noise generated during sharpening can be quite loud, so it is crucial to wear ear protection. You can choose between earplugs or safety earmuffs, whichever you find more comfortable. They will help reduce the noise level and protect your hearing.

Respiratory Protection

Sharpening a table saw blade can create fine dust and particles that can be harmful if inhaled. A dust mask respirator is essential to protect your lungs and respiratory system from these particles. Look for respirators specifically designed for dust protection.

Clothing

Wear long sleeves and pants made from durable material to protect your skin and body from any flying debris or sparks. It is also recommended to tie back long hair and avoid wearing jewellery that could get caught in the machinery.

Push Stick

When testing the sharpness of the blade, always use a push stick to guide the wood towards the blade. This will help you maintain control and keep your hands at a safe distance from the blade.

Machine Guarding

Ensure that your table saw has proper guarding in place. This includes a self-adjusting guard above the table that adjusts to the thickness of the material being cut. Additionally, always guard the portion of the blade below the table to protect against potential contact when reaching underneath.

Kickback Prevention

Kickbacks can occur when the blade catches the stock and throws it back towards the operator. To prevent this, use a spreader or anti-kickback fingers to hold the stock down. Additionally, always use the proper blade for the cutting action and maintain the correct blade height.

Brake

Consider attaching a brake to the motor's arbor to bring the saw to a quick stop when the power is cut off. Alternatively, remain at the saw station until the blade comes to a complete stop after shutting off the motor.

Proper Blade Care

Only sharpen the inner edge of the blade that has carbide layering responsible for the bluntness. Maintain sharp blades by regularly cleaning and inspecting them for any signs of rust or layering within the edges and crevices.

Removing the blade

• Disconnect the Power: Before beginning any work on your table saw, it is crucial to disconnect the power source. Unplug the power cord from the wall socket to ensure that the saw is completely powerless. This simple step can prevent accidents and injuries.
• Remove the Blade Guard and Miter Gauge: Accessing the blade may require removing some parts of the saw. Start by removing the blade guard, which protects the blade during operation. Then, remove the miter gauge, a tool used for accurate crosscuts.
• Slide the Rip Fence: The rip fence is a guide that helps keep the wood straight during cutting. Move it to the side to provide better access to the blade and surrounding area.
• Raise the Blade: Adjust the blade to its highest position to make it easier to work with. This position will give you more space and a better view of the blade and its components.
• Secure the Blade: Place a small block of wood, or a scrap piece of wood, against the blade. This step is crucial for safety as it prevents the blade from accidentally turning while you work.
• Remove the Nut and Washer: Locate the nut and washer that secure the blade in place. Using a wrench, turn the nut counterclockwise, toward you, to loosen and remove it. Be careful not to drop the nut or washer, as they can be difficult to retrieve from inside the saw.
• Remove the Blade: With the nut and washer removed, you can now take out the blade. Set it aside in a safe place while you continue working. Remember to handle the blade with care, as even a dull blade can cause injuries.
• Clean the Arbor: Before installing a new blade, it is good practice to clean the arbor, which is the shaft that holds the blade. Use a brush or compressed air to remove any sawdust or debris that has accumulated.

By following these steps, you can safely and effectively remove the blade from your table saw. Always refer to your owner's manual for specific instructions related to your particular model, as some variations may exist between different table saws.

Using a diamond blade

Preparation:

Before starting, ensure your table saw is unplugged and cannot start accidentally. The next step is to put on safety gear, including safety goggles, gloves, ear protection, and a dust mask respirator. It is crucial to take these precautions to avoid injuries and protect yourself from dust and debris.

Now, you need to remove the table saw blade from the saw. Look for a blade release switch; if your saw doesn't have one, use a wrench to loosen the arbor nut and release the blade. Once the blade is removed, secure it safely for sharpening. If you're using the diamond blade technique, ensure the blade is laying flat on a surface or a special jig.

Inspect and Identify:

Before sharpening, inspect the blade for any damage or issues. If the blade is dirty, rusty, or has signs of chipping or fractures, it is recommended to clean it before proceeding. Additionally, identify the type of blade you are sharpening. If all the teeth are pointing in the same direction, you can sharpen them in one pass. More complex tooth arrangements may require multiple passes.

The Diamond Blade Technique:

For this method, you will need a continuous-ring diamond blade and a jig, which can be a simple, homemade design. Install the diamond blade in your table saw, ensuring it is thinner than the gullets between the teeth of the blade you are sharpening. This method works best with carbide-tipped blades, as older and cheaper blades may not be worth the time and effort.

Once the diamond blade is installed, you can turn on the table saw. To sharpen, insert the diamond blade between the teeth of the dull blade. Gently push the tooth against the diamond blade, matching the angle of the original tooth angle. This process will grind away the dull edge and create a new, sharper one. Repeat this process for each tooth, ensuring you cover all the teeth.

Final Steps:

When all the teeth are sharpened, remove the diamond blade from the saw. Clean the blade before putting it away to remove any metal particles and carbide dust, preventing tarnishing or rust. Finally, reinstall the sharpened saw blade and test it by cutting through a material. It should now cut smoothly and efficiently, indicating that the sharpening process was successful.

Cleaning the blade

Cleaning your table saw blade is a straightforward process that can help prolong its life and improve its performance. Here is a step-by-step guide on how to clean your table saw blade:

Step 1: Prepare the Cleaning Solution

Get a shallow container that can fit the blade and is deep enough for submerging it. Mix your chosen cleaner according to the instructions. For regular cleaning, a mixture of one part cleaner with three parts water is typically sufficient. However, for more serious gunk buildup, you may use the cleaner directly without diluting it. Always refer to the manufacturer's instructions for specific portions and recommendations.

Step 2: Soak the Blade

Carefully remove the blade from your table saw, being mindful of the sharp teeth. Unplug the saw or turn it off before beginning this step. Place the blade into the prepared cleaning solution and let it soak for a few minutes. The soaking time may vary depending on the level of dirt and grime on the blade.

Step 3: Scrub the Blade

After soaking, use a toothbrush or a small brass brush to scrub the blade's teeth and any areas with gunk or residue. For Teflon-coated blades, a toothbrush is recommended over a brass or stainless-steel brush. You can trim the bristles of the toothbrush to half their length to increase its effectiveness. For stubborn pitch buildup, laminate sample chips can be used for scraping.

Step 4: Rinse and Dry the Blade

Rinse the blade thoroughly with clean water to remove any remaining cleaning solution. Ensure that all areas, including between the teeth, are free of residue and damp spots. Dry the blade completely using a cloth, paper towel, or microfiber cloth. Rub in the direction of the cutting edge to avoid any accidental cuts. You may also use an air compressor or a hairdryer to ensure all moisture is removed.

Step 5: Apply Rust Inhibitor and Lubricant (Optional)

Apply a rust inhibitor, such as WD-40, to all metal surfaces of the blade to protect it from corrosion. Additionally, you can apply a blade lubricant to help prevent resin buildup and create cleaner cuts. This step is optional but can enhance the performance and longevity of your blade.

Additional Tips:

• It is recommended to clean your table saw blade regularly, even if you don't use it frequently. A quick cleaning two to three times a year is suggested.
• Before soaking the blade, you can use a stiff wire brush to remove any large chunks of dirt, sawdust, or glue.
• Always practice safety when handling the blade, as the teeth remain sharp even when dull. Wear protective gear, including gloves, and be cautious when working near the sharp edges.
• For carbide-tipped blades, use a special abrasive cleaner rather than a wire brush or steel wool to avoid damaging the blade.

Testing the blade

To test the blade, take a piece of scrap wood and cut it on the table saw, using the rip fence as a guide. It is important to use a push block or push stick for safety. After cutting, inspect the edges of the wood for any signs of burning or chipping. If the edges are smooth, then you have successfully sharpened your blade. If not, you may need to repeat the sharpening process.

It is also important to note that a blade might still be sharp enough to cut you, even if it is dull. So always be careful when handling a saw blade, even a dull one.

Frequently asked questions