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Can't leave well enough alone #1: Intro and first hack share

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Blog entry by WorksInTheory posted 03-07-2018 06:10 AM 686 reads 0 times favorited 4 comments Add to Favorites Watch
no previous part Part 1 of Can't leave well enough alone series Part 2: 2nd Hack to Delta Cruzer Miter Saw - the Shadow Line »

Hi, sometimes it feels like I collect tools more than actually use them. And then I can’t leave well enough alone and I have to hack them. I just get ideas or get inspired by dungeons else’s and then have to make it reality. As a kid I always loved taking apart perfectly good electronics or toys and pot them bsck together or MacGyver a tic somehow… which then also leads me to horde random things in case I could use it in some hack.

With this first blog posting, I’ll share a recent episode of fiddling. My brand new Delta Cruzer miter saw needed nothing done to it. But of course I made a . Zero clearance insert to replace the stock one. I don’t know why they make stock inserts with such gaping gaps. Didn’t they used to come as a solid piece of plastic the you would cut a line into? Anyways at first I was going to make it matching blue but at the last minute went for the bright green.

Next I decided to take apart one of those free Harbor Freight LED flashlights and make a shadow line cut good slash work light. I don’t know why such a premium miter saw did not come with a laser or shadow line guide.

https://youtu.be/3ryn-H0uvoY

Took me a while as I was figuring things on the go. Wife wasn’t happy with all the time spent on these projects ha. I also ended up scraping a few different approaches after trial and error and landed on this one which was simplest.



4 comments so far

View gauntlet21's profile

gauntlet21

4 posts in 237 days


#1 posted 03-13-2018 02:28 PM

I’ve got the same idea about making my own ZCI. I can’t find one pre-fabbed by anyone yet since the saw is still so new so I’ll get to do that myself. For my table saw I just bought a Leecraft one and used a router with pattern bit to make 10 or so copies for all of the various blades/dados that I have. In a YouTube review that I watched from Dec. 2017, the guy said he contacted Delta about a Lazer/Shadowline and Delta told him it’d be coming out in early 2018 along with some vacuum attachment accessories. Don’t know if I believe it or not yet since it’s March but I guess we will see. Good on ya.

View WorksInTheory's profile

WorksInTheory

141 posts in 1629 days


#2 posted 03-13-2018 05:25 PM

Thanks for the comment. Agreed don’t hold your breadth on those accessories. Plus likely overpriced. I’ve also come to believe that Delta customer service is not great as they are not responsive to any of their channels of contact. For example they finally responded to my communication 3 months later only after I wrote some follow up emails basically saying “hey what gives?”.

On the ZCI, I measured the width and length first and cut a board to the profile. Then I lined up the 2 parts of the stock one to the sides and traced the radiuses on the ends (the profiles are different on each end). You have to do it this way because the stock is not a single piece and has that big space in between. Finally I just used paper and overlayed onto the stock pieces and did a pencill coloring to pick up the locations of the countersunk tabs where the screws go in and then taped it down from there and did the drill work.

Check out my next blog post where I added a shadowline for little money.

View gauntlet21's profile

gauntlet21

4 posts in 237 days


#3 posted 03-21-2018 08:46 PM

I’m currently looking for a better clamp for the Cruzer and am not sure if either the Ridgid or Festool miter saw clamps would be compatible. The one that comes with the Cruzer is ridiculously cumbersome. That, the lack of laser or shadowline, and the dust collection are features that clearly were overlooked. It’s still a great saw but it would have been nice to see some competitive intuition from Delta regarding those features which are standard even on entry level miter saws. Well, dust collection isn’t good on any miter saw unless you’ve got a Festool Kapex I am certain. Anyways, I figure I’ll order the Ridgid quick clamp and see if it fits. By my measurements it will either be really tight or I’ll need to hollow out a little from the tubular seat behind the fence in order to get a 5/8” rod to fit in a 0.603” hole. It’s nearly impossible to get any of the exact dimensions for those parts so I’ll just have to wing-it and make adjustments based on the initial results.

View WorksInTheory's profile

WorksInTheory

141 posts in 1629 days


#4 posted 03-21-2018 10:19 PM

gauntlet21 – I’ve been thinking about this one too. Let me know how it works out. Here’s another idea I was toying with but haven’t executed. Harbor Freight has these C-clamps that are quick release. I was thinking to cut off the bottom curve and then grind down spine either to the space of the hole in the saw or to fit into a dowel that fits into the hole in the saw. Maybe you would want to try and let me know how it goes. I am not too experience nor have many tools around handling and manipulating metal.

The clamps come in 4” and 6” and only $5.99 and $7.99. https://www.harborfreight.com/4-inch-quick-release-c-clamp-4137.html

would be interested in ideas around this to tweak it to be even better too.

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