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Grizzly 1023 Switch Relocate and Safety Stop

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Project by lightweightladylefty posted 05-29-2010 06:45 AM 2997 views 3 times favorited 16 comments Add to Favorites Watch

About a year ago I purchased a used Grizzly 1023 tablesaw which had been poorly maintained. The previous owner had sawed mostly pine and must never have cleaned it. All the parts were caked hard with pitch and sawdust and the entire base was packed full of sawdust. I spent many hours cleaning it and removing the rust from the top.

When I got the saw, the switch was mounted similar to the photo in the back of the Grizzly manual (photo top right) except that the mounting plate was reversed to make it easier to reach the screws, but making it protrude an additional inch. It was in the way every time I tried to walk around the saw, catching my hip on it. And the horizontal location did not lend itself to intuitively knowing which button to push to turn it off.

Since I was unhappy with that location, I decided to remount it similar to the mounting shown on the front page of the Grizzly manual (photo middle left), except I extended it out on a bracket making it 3 inches closer to the front since, for me, it was virtually unreachable so far back. After attempting to use it in that location for the past few months, my husband and I decided it was an accident waiting to happen. The reach was inconvenient and we would invariably fumble for the off button and have to bend down to look. [Oops! There goes an eye.]
:-(

So before disaster occurred, I rewired the switch; (it was previously wired out both ends). My husband made another mounting plate so I could hang it vertically behind the front rail. I then made the flip-down red stop, and we are quite pleased with its performance.

Center right photo shows the bent hinges I found (25 cent each) to attach the safety stop. Bottom left is just another photo angle and bottom right show the safety stop flipped up. I routed two L-brackets into the back of the wooden safety stop, then spray-painted it red (to please my husband). ;-)

Any of you Grizzly 1023 owners out there: do you actually like Grizzly’s mounting options? We’re perplexed that they have manufactured a saw model for so many years and not provided a better switch location.

(Some might not consider this a project; but for me IT WAS A PROJECT! . . . and it does include a tiny bit of wood. Besides, projects are a little faster for me to upload with dial-up.)

-- Jesus is the ONLY reason for ANY season.





16 comments so far

View a1Jim's profile

a1Jim

112089 posts in 2232 days


#1 posted 05-29-2010 07:18 AM

Looks like a great fix.

-- http://artisticwoodstudio.com Custom furniture

View Eagle1's profile

Eagle1

2066 posts in 1719 days


#2 posted 05-29-2010 11:48 AM

I really like the new stop switch. I have noticed since getting my new craftsman TS. It has the leg stop swtich ( if thats what you want to call it) Mounted of the left. all of them might be that way, I really havent noticed on all TS. Its easier to push it with the left leg..

Tim:

-- Tim, Missouri ....Inside every older person is a younger person wondering what the heck happened

View docholladay's profile

docholladay

1286 posts in 1713 days


#3 posted 05-29-2010 02:35 PM

I put a safety switch on my old Delta a year or so ago in about the same place. Only problem is, my fat belly ocasionally turns the saw off by accident. Better that than to not be able to get to the switch when you need to.

-- Hey, woodworking ain't brain surgery. Just do something and keep trying till you get it. Doc

View Dusty56's profile

Dusty56

11659 posts in 2343 days


#4 posted 05-29-2010 03:13 PM

Excellent conversion : )

-- I'm absolutely positive that I couldn't be more uncertain!

View Woodwrecker's profile

Woodwrecker

3608 posts in 2230 days


#5 posted 05-29-2010 03:20 PM

Smart safety addition.
small start switch + big stop switch = safety.

-- All glory comes from daring to begin. ~ Eugene F. Ware

View Matt Franck's profile

Matt Franck

7 posts in 1792 days


#6 posted 05-29-2010 06:37 PM

I own the same model series (the 1023”S” for single phase) and made a similar modification. Rather than make a new switch, I purchased one that came with the off “paddle”. The purchase was required because I broke the stock one—long story. I moved the switch to the same location for similar reasons of accessibility with my left hand.

It does seems strange that Grizzly hasn’t provided a better solution on a mature product like the 1023 series. I shouldn’t complain—if they figure it out they could charge a much higher price. The other annoyance was the hinged motor hood which was easily 3/8 of an inch out of alignment requiring some exploration of sheet metal modification.

The only modification to the saw I’m happier about than the switch change is the installation of Biesemeyer fence. I bought my 1023S off eBay so I actually spent more on the fence then the saw. Worth every penny IMO.

View trimmer's profile

trimmer

90 posts in 2096 days


#7 posted 05-29-2010 07:10 PM

That must be an older version of the 1023. My 1023 is 12 yrs/ old and it come mounted on left side where you moved yours to. Very neat idea of your off paddle, you got me thinking now.
Thanks for the idea!!!!!!

View lightweightladylefty's profile (online now)

lightweightladylefty

2646 posts in 2367 days


#8 posted 05-30-2010 04:20 AM

Thanks for all the words of encouragement. I thought it could give someone else an idea for a conversion in case they aren’t happy with the switch placement on their tablesaw.

Matt, My saw came with a ShopFox fence which had never been properly adjusted. If I adjusted it 90 degrees (vertically) to the table, it wouldn’t move. ShopFox told me to grind down the part that was rubbing because it couldn’t be adjusted. After tinkering around more with it, I realized that if I ”Loctited” the nut, I could readjust it properly. So much for professional advice! I can only dream of a Biesemeyer!

Trimmer, I don’t know how old the saw is since I purchased it used, but I received it with the switch on the left but it was mounted horizontally and protruded about 4 inches from the rail (similar to what is shown in the back of the instruction manual). After remounting it on the right underneath and realizing that was even worse, I came up with the vertical mount with safety stop mounted behind the rail on the right so that it only protrudes enough to easily shut it off.

L/W

-- Jesus is the ONLY reason for ANY season.

View tooldad's profile

tooldad

657 posts in 2369 days


#9 posted 05-30-2010 04:28 AM

the switch on the left is where I have them in the school shop. It demonstrates and reminds the students to stand on that side of the fence and face the fence. We use the Grizzly H8243 for most of our tools. It has the big stop paddle.

View Jim Jakosh's profile

Jim Jakosh

11466 posts in 1760 days


#10 posted 06-23-2011 01:17 PM

Smart thinking on that switch location. I have a Ryobi with a lower switch but it has a bid OFF paddle on it, when I get through cutting, I can hit it with the pusher stick very easily. I don’t ever touched it with my hand!
I have purchased Grizzly paddle switches for three more of my tools and I love ‘em.

Thanks for posting!!

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View lightweightladylefty's profile (online now)

lightweightladylefty

2646 posts in 2367 days


#11 posted 06-24-2011 05:56 AM

Jim,

Thanks for your comment. LJs has really helped me to think through safety issues more clearly and get good ideas for implementing changes.

L/W

-- Jesus is the ONLY reason for ANY season.

View stumpg's profile

stumpg

1 post in 1204 days


#12 posted 10-18-2011 07:04 PM

Thanks L/W for a great idea. I’m new to LJ and researching for a potential purchase of 4yr old 3 HP Grizzly 1023 ($675) with mobile base and folding rear extension table. The 2 upgrades I would want to make for this saw right off the bat would be a adding a riving knife and stop switch paddle. Found the riving knife addition in this forum for $140 (BORK) and YOUR great idea for basically free! Thanks again, this and other great reviews on LJ have been invaluable. v/r, Jim

View lightweightladylefty's profile (online now)

lightweightladylefty

2646 posts in 2367 days


#13 posted 10-19-2011 04:27 AM

Jim,

It’s rewarding to know that someone has found this information helpful. My saw could use a riving knife/splitter, too. I keep thinking that I’ll make a zero clearance plate with splitter and see how that works.

Thanks for your encouragement.

L/W

-- Jesus is the ONLY reason for ANY season.

View Paul David Soto's profile

Paul David Soto

141 posts in 1261 days


#14 posted 12-29-2011 02:24 PM

@lightweightladylefty – Thanks for posting your project! Not only did it inspire me to purchase the old table saw ($350), but it also reassured me that I’ll have someone else to ask for advice when I run into issues like these. Hope to keep you in my friends list.

-Paul

-- - As a woodworker, it could be interesting sometimes waking up in the morning and asking, "Lord, what will you have me do today?" -Noah

View lightweightladylefty's profile (online now)

lightweightladylefty

2646 posts in 2367 days


#15 posted 12-29-2011 07:45 PM

Paul,

Best wishes with your “new” 1023. It sounds like you got a great deal. I had an awfully lot of work to get mine into shape. It had been used mostly for cutting pine and the inside was nearly fossilized from all the pitch! I hope we’ll both have many good years with our 1023s!

L/W

-- Jesus is the ONLY reason for ANY season.

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