|Project by TD69Mustang||posted 05-25-2009 11:37 AM||9368 views||18 times favorited||17 comments|
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!