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Alaska Jim's Comments of the Day #19: A new LJ Mentored Project......Integrating my old saw and the Super Sled into the Shop

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Blog entry by Jim Bertelson posted 03-02-2010 05:39 AM 834 reads 0 times favorited 9 comments Add to Favorites Watch
« Part 18: Sled mostly Done, Fence Calibrated, Dado Set in action......busy shop weekend. Part 19 of Alaska Jim's Comments of the Day series Part 20: More progress on the Crosscut Sled, a Travel Stop »

Put on your thinking bonnet, because this is all interrelated stuff. If this seems complex, it is, mostly because there are contingencies based on performance, and I built my sled with these things in mind. Things like splitters have nothing to do with the sled.

1) Splitter. I have ordered Incra microsplitters, the ones with a metal skeleton, and they are in the mail. That will be my splitter solution. I agonized over this a long time, but if I don’t like something about them….....I will engineer something better along the same lines and build them….....many virtues to having a ZCI (zero clearance insert) mounted splitter…...(-: ZCI’s are a snap to make, and modify. Thanks to the reviews on LJ’s about this splitter.

2) Guards. Guards are high on my list of essentials. I never do a rip without one. Never. But I used that sled without a guard, because I am not using it in production mode, and they have a much better safety profile. Much like my radial arm saw.

But the sled will get a guard, most likely a three sided guard that will be pretty safe, and will tend to trap dust.

Now comes the complexity because there are contingencies.

I am going to build a guard for when I am not using the sled that is an overhead mobile guard, meaning multiple mounting points. If my new idea works it will not need dust control integrated with it. With 2 or more mounting points, and there are a bunch of designs out there describing how to make it sit in place. Like my lamps on my central pillar, you do not need an extremely robust mounting system, because you can place it on a different mount that doesn’t interfere with the workpiece, and it does not need a long reach.

3) Dust control. With a contractors saw there is this large open area in back. How to control dust?.........make a containment box…......and that is my secret weapon…......the outfeed table, or better put, the outfeed cabinet. It will work even with miter cuts. And be a detachable part of the overall TS cabinet, the TS cabinet will also include a router table in the extension. So with dust contained, including revisions to the other slots in the main TS cabinet, there will be a strong negative pressure in the saw cabinet, at least with my DC, which I find pretty impressive for what I paid for it.

So once you have strong negative pressure, how to use it to collect the dust near the blade.

Any dust coming through the kerf in the ZCI will of course be trapped. And here is the thought….......

Why not a dust port in the ZCI, which should probably be a slot?

Lot of wasted space on that ZCI. If you are using an overhead guard it will contain the air flow, and perhaps (the contingency) trap the dust. Same with the sled. You don’t need a full slot in the sled, just a series of holes, which, as they pass over the ZCI will become subject to the suction.

4) Sled Availability. I narrowed my sled to 44 inches, it was designed at 48 inches. 48 inches is awkward, if you are trying to house it, because about 48 inches is a good cabinet size looking at sheet goods. So I cut it back.

I am going to house the sled in the outfeed table, with a pivoting sub-cabinet that makes it line up with the TS and you pull it out, hence it needed to be narrower.

I want the turn over to be about 30 seconds with minimal physical effort to change from normal to sled usage.

And all this will be the subject of an LJ Mentored Project that ought to create a lot of interest and input.

I sure hope this creates some interest, because I am sure I am going to need your help….....

-- Jim, Anchorage Alaska



9 comments so far

View lew's profile

lew

10056 posts in 2422 days


#1 posted 03-02-2010 05:45 AM

I think instead of a slot in the ZCI, a few holes in the wider section may work better. Maybe located nearer the end where the blade is moving down into the insert. Just a thought.

Lew

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View Jim Bertelson's profile

Jim Bertelson

3666 posts in 1831 days


#2 posted 03-02-2010 06:00 AM

Lew
This is one of the issues, slot versus holes, where to put them. ZCI’s are easy to make, so I will make a bunch of blanks and experiment. Wow….....you were fast on this, you are a fast read. I will be depending on a lot of input….....thanks Lew.

I hope everyone will have fun working with this….......

Of course, next comes some Sketchup stuff, unfortunately, probably about 2 weeks from now…....a bunch of call duty coming up. And I have the temporary router table and the computer cart to do. But I seem to be on a roll right now….....we’ll see…..

-- Jim, Anchorage Alaska

View David Craig's profile

David Craig

2135 posts in 1775 days


#3 posted 03-02-2010 06:13 AM

I’m sorry Jim, I thought the computer cart and the router table were all going to be incorporated into the super sled. I suppose that means that I should not hold my breath on waiting for it to be a “hopper” as well :)

Glad you are making progress and sounds like an amazing contraption. Kudos to you for taking a sled farther than any man has gone before…

David

-- There is little that is simple when it comes to making a simple box.

View Jim Bertelson's profile

Jim Bertelson

3666 posts in 1831 days


#4 posted 03-02-2010 06:27 AM

David Craig
You are a devil, you, we’ll see how it goes. If you have any suggestions, please help out. You are a very practical guy like me, having watched you for a while…......please chime in. I like your stuff.

-- Jim, Anchorage Alaska

View David Craig's profile

David Craig

2135 posts in 1775 days


#5 posted 03-02-2010 03:25 PM

Good observation Jim, my mom used to say that she thought I was possessed until I turned 8 :) At this point, I am just admiring your ingenuity. Honestly, I would have just made a sled, but yours…wow! I find myself singing Secret Agent Man every time I look at it.

David

-- There is little that is simple when it comes to making a simple box.

View Jim Bertelson's profile

Jim Bertelson

3666 posts in 1831 days


#6 posted 03-02-2010 04:51 PM

David
The sled does work well as is, and will be put to use immediately prior to doing the final embellishments, meaning the miter arms, T-track on the fence, and stop blocks. Those may wait a bit. I may get to the stop block before the miter arms. This morning, if I have a little time, will start on the temporary router table mods. Then I am ready to build the miter arms when I want to.

-- Jim, Anchorage Alaska

View stefang's profile

stefang

13104 posts in 2000 days


#7 posted 03-02-2010 10:32 PM

It is strange Jim, but it seems a lot of people out there get more fun from building jigs and other shop made tools than actually turning out projects. I think I might be in the same boat. Perhaps it’s more of a challenge to make something that can make something rather than just making something.

-- Mike, an American living in Norway.

View Jim Bertelson's profile

Jim Bertelson

3666 posts in 1831 days


#8 posted 03-03-2010 06:32 AM

Mike
I have an excuse, I am a neophyte to the hobby part. But I always knew the shop would be at least half the fun for me. What the heck, it is still part of the hobby. But I actually know what I will build for my first hobby project, if I ever get there….............

In the mean time, just having a good time….........(-:

-- Jim, Anchorage Alaska

View Jim Bertelson's profile

Jim Bertelson

3666 posts in 1831 days


#9 posted 03-03-2010 06:34 AM

Mike
I think it is just the frustrated engineer part of me….......thats what I started out to be. So now I can pretend…......(-:

-- Jim, Anchorage Alaska

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