DIY Table Saw Router Extension Wing #4: DIY Router Safety Switch

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Blog entry by Mike_D_S posted 06-14-2016 04:34 AM 1035 reads 0 times favorited 1 comment Add to Favorites Watch
« Part 3: Finally getting somewhere- lift installed Part 4 of DIY Table Saw Router Extension Wing series no next part

In the process of finishing the setup of the router, I wanted to get a nice router safety switch. I wanted a mag switch, but after looking around and realizing that a new one was going to be $50+, I decided to do some additional DIY.

So I used the following parts to make up my own switch:
1. Woodstock D4160 magnetic paddle switch $12 from Amazon
2. PVC single gang junction box with 3/4” conduit fitting on bottom $6
3. Single outlet $3
4. Metal single gang cover $2
5. Cord from cheap power strip $4
6. 1/4” slip on spade connectors (I had these already, but maybe $2)

Total cost $27 (for me). Last task is to cut a mounted frame out of 3/4” ply and attach it to the table tomorrow.

DISCLAIMER: The following description was written by a guy who has shocked himself more than once. I’m not an electrician, just a cheap-ass with a lot of tools. Electricity is dangerous stuff and incorrectly wiring things can cause fires, damage to your equipment, death and lots of other worse things. This is not super difficult, but if you don’t know what hot and neutral mean and you don’t know which blade on a plug is the hot, then you should probably just buy a prebuilt switch.

Assembly Steps.
1. Cut out the back of the PVC junction box to allow the single outlet to fit into the box. Make sure you leave enough to be able to screw the outlet into the box. Mark holes for mounting the outlet, then drill and tap the holes. The tapping is probably not necessary since this is plastic, but I have the taps, so I did it.
2. Disassembly the cheap power strip and discard everything but the cord. Strip back the exterior of the cord, leaving about 14” of cord intact. Separate the wires and remove the stripped covering.
3. Slip the newly exposed wires into the junction box through the 3/4” conduit penetration and tie a knot in the cord at the point you stripped the exterior covering off. This is for strain relief to make sure you don’t accidentally pull the guts out of your switch.
4. For wiring, you’ll need about 4 or 5 inches of the hot and neutral wide coming from the cord to go to the mag switch and one piece each of hot and neutral line about 4 inches long to go from the mag switch to the outlet. i was able to cut the needed wire from the extra wire on the stripped cord.
5. Strip about 3/16” off the end of the hot and neutral from the cord and off one end of the small pieces of hot and neutral wire you cut above. Then attach the spade connectors to the end of these pieces. Make sure you get a good connection here. Most of the spade connectors will have crimps, but I usually do a little tack solder as well to help hold it together.
6. Connect the spade connectors to the mag switch following the instructions for the switch. Cord to the input and the short piece to the output.
7. Attach the switch to the front of the junction box wtih 6-32 screws. make sure to feed the ground from the cord and the two short pieces from the switch output through the back of the box.
8. Wire the outlet to the switch and the ground line from the cord.
9. Install the outlet using the holes you drilled way back in step 2, then mount the single gang cover to the outlet.
10. plug in and test (in my case I tested it using the light in the living room, annoying the hell out of my wife flipping the light on and off 500 times).

-- No honey, that's not new, I've had that forever......

1 comment so far

View htl's profile


2176 posts in 620 days

#1 posted 06-14-2016 02:17 PM

Making small parts I need to turn my Dewalt saw on and off way to much so have been thinking along your lines of building a switch to use and it can be easily replaced at any time so would save my dewalt’s switch. So thanks for the push to get er done.

-- There's a hundred ways to do anything, alot depends on the tools at hand.

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