I spent a few hours last night disassembling the 2 Biesemeyer T-Squares and removing the laminated plywood faces. Besides a nasty splinter in my thumb, the process left me with a bigger problem: How to re-face the T-Squares.
I do not want to purchase the Beisemeyer replacement face. They are too expensive and there is just something fundamentally wrong with a woodworker paying 70 dollars for a 3×42 piece of laminated ply. I have come up with the following options, but am not sure which is the best choice:
- Laminated Plywood (1/2 inch?, 3/4 inch?, not sure which species)
- UHMW Polyethylene: I am not sure how flat this is and how to attach this to the T-Square body
- MDF or Laminated MDF (1/2 inch?, 3/4 inch?)
- Phenolic ??
- Something else ???
I have a sheet of UHMW that I purchased and it is cupped, bowed and twisted. I was going to see if I could glue this somehow to a piece of MDF or Ply, but the gluing process seems a bit too complicated with this material. I was going to try screwing it from the backside, but because it is so warped, I do not think that this option would be good for a fence.
Laminating the Ply or MDF
Then for my choice of laminates, I was wondering if anyone has ever used Formica’s Micro-dot laminate. It is the same one that Kreg uses on its router table. I also have no experience in laminating with anything other than wood, so I am not sure what else is out there.
I feel that I am in a good position to experiment here. I have 2 T-Squares for the saw, so I could implement 2 options and see which one I like. I could also build out one square as an auxiliary fence and make it so that I could easily attach jigs, guides and sacrificial fences to it.
If anyone has any experience with this, or could point me to some resources I would be very grateful for your help.
Now onto the next question: When I am done, do I get a Powermatic or a Biesemeyer decal for the top of the fence? :)