| Project by screwge | posted 182 days ago | 1047 views | 6 times favorited | 15 comments |  |
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The magnetic on/off switch that came on my table saw is so small that it is a safety hazzard to turn it off. The last thing I need while cutting a large sheet of plywood or whatever…..is to divert my attention from the blade to fumble around with the on/off switch…..oops! there goes a finger!
I thought I would be able to find a replacement with one of those nice large knee pads, but look as I might, there were none to be found.
The next best thing…. Build my own.
I went to a local hardware store and found the same type of phenolic plastic that is on the fence.
I then cut the basic shape on the band saw then…
I drilled the hole for the hinge rod on the drill press then…
I cut out the mounting plate from the knee pad on the band saw and rounded the edges with a sander (should have used a round over bit on the router, the sander left tiny “hairs of plastic” hanging)
I then re-bored the holes on both sides of the knee pad to be just a little bit bigger than on the mounting plate, so that the knee pad would swing easily and not bind.
I removed the face of the switch cover (after unplugging it – of course) drilled the mounting holes and mounted the plastic with 4-#6 stainless machine screws, bolted on from the back using lock washers. NOTE: you must make sure that no part of the bolt comes near any electrical connection inside the switch cover – preferably before any holes are drilled, as this could be very dangerous.
I then cut the hinge rod for length and tapped it into place.
Now, when I cutting anything on the saw I have a convenient and safe way of shutting it down with my knee so I don’t have to divert my attention and lose a finger. I do still have all my fingers! thank GOD!!!!
Hope this helps
-- Imagine It... Build It... Enjoy It!
15 comments so far
jockmike2
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7302 posts in 1140 days
posted 182 days ago
Very imaginative and right on. Maybe someone else will pickup on the idea and you will have saved a finger somewhere. Good job.
-- Mike. mwurm13@yahoo.com
Vince
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186 posts in 323 days
posted 182 days ago
I like it…great idea.
-- Vince
spanky46
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736 posts in 284 days
posted 182 days ago
Nice job! All those digits are important, lets keep them all!
-- spanky46 -- Never enough clamps...Never enough tools...Never enough time.
Splinterman
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4826 posts in 255 days
posted 182 days ago
Good OH&S practice here.
-- I will just keep doing it till I get it right.
PurpLev
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2745 posts in 542 days
posted 182 days ago
very nicely done! a most important reason, and very well executed.
where did you find the UHMW material ? which local store held it in stock?
-- When in doubt - There is no doubt - Go the safer route.
lew
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4484 posts in 649 days
posted 182 days ago
Very well engineered!
Thanks for posting this!
Jerry
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80 posts in 432 days
posted 182 days ago
Looks great and more importantly…...Safe
thanks for sharing!!
-- Jerry - Rochester, MN *Whether you think you can or you can't, you are probably right*
a1Jim
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16696 posts in 471 days
posted 182 days ago
another professional looking jig nice design and clean build thanks for the informative help
-- Jim from Heirloom Woodshop Southern Oregon
Christopher
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563 posts in 814 days
posted 182 days ago
Thats frikken ingenious!
-- "That Government is Best that Governs The Least."-Jefferson
SCOTSMAN
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2238 posts in 479 days
posted 182 days ago
A great Idea I made one like this and it fell off so I eventually bought ( an industrial footswitch cut off switch )and added it to my saw as well as a hand punch stop switch.Good thinking sir well done my friend Alistair
-- excuse my typing as I have a form of parkinsons disease
screwge
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37 posts in 184 days
posted 182 days ago
PurpLev – the UHMW phenolic plastic is 1/2” thick and I purchased it at a local independently owned ACE hardware franchise store. However, there are also plastic supply stores in our area that will sell retail. Tap Plastics is one source that has locations across the U.S.
-- Imagine It... Build It... Enjoy It!
Dusty56
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3460 posts in 581 days
posted 182 days ago
This is the nicest shopmade stop switch activator that I’ve seen . I worked in a “professional” shop and they just had a piece of plywood hanging from a piece of wire to do the same thing. VERY crude , but somehow it worked. I believe that you’ve just solved my only issue with my JET cabinet saw for me . I Thank you , and my fingers thank you as well : )
-- You know you're getting old when you know the difference between you're (you are) and your (belonging to you) AND how to use them in a sentence .
Wade Putnam
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63 posts in 623 days
posted 179 days ago
Great design and workmanship.
I will build one of these for my Jet this week end.
Thanks for sharing
-- Wade, Nashville, www.casetn.com
Grumpy
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14920 posts in 744 days
posted 178 days ago
Great idea Screwge. I have a factory made one on my TS, comes in very handy.
-- Grumpy - "Always look on the bright side of life"- Monty Python
Dusty56
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3460 posts in 581 days
posted 177 days ago
http://www.mlcswoodworking.com/shopsite_sc/store/html/smarthtml/pages/routacc1.html#router_power_switch_anchor
MLCS is having a sale on Safety Switches right now : ) 110V and 220V
-- You know you're getting old when you know the difference between you're (you are) and your (belonging to you) AND how to use them in a sentence .