Major Scrollsaw Modification and Upgrade

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Project by jerrells posted 03-20-2013 04:38 PM 4235 views 8 times favorited 6 comments Add to Favorites Watch
Major Scrollsaw Modification and Upgrade
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After using a scroll saw for about three years and having lots of “I wish” ideas built up I used a vibration issue to make most of them happen. My DeWalt starting vibrating more than I thought it should. So I quickly turned to Rich Hutchenson’s web-site and found information from him and also posted, information from Ron Brown. Well generally is was disassembly time, check and lubricate all connections and joints. and then “O YES” reassembly.

The main picture shows the saw in it’s current condition as of today. NO more vibration out of norm AND O YES a few of those “I WISH” items added.

First of all I use a surge protector as the main on/off control for everything on the saw. I was positioned where I had to stand a reach to use it. No more. The picture below shows it repositioned higher and at a 45 degree angle that I can reach from my stool

Next, I wanted better control and mobility with the saw. As I have posted before, I purchased on old cabinet and refitted it to serve as my base. Now I have added corner rollers from Rockler and widen the base. Much better control.

Having already had sinus issue this spring I said it was time to install a dust collection system. I researched Lumberjocks, the web, blogs and anywhere I could find information. Most everything told me to come up with a good idea and it may need modification later. What I came up with was using some 1 inch PVC pipe with various fittings. The tee is where I plug in the hose from my buckethead vac. Under the table I used a wide nozzle fitting from my larger shop vac. Can’t really see in the picture but I had to chop off on corner of the end of the fitting so it would clear under the table. On the back of the manifold I put a threaded connection for a piece of clear flex hose that runs over the saw to the top of the table. The system works fine in initial test but I sure there will be a few changes.

Now the last, and perhaps overkill, was the light and fan mounting arm. When I had the saw stationed against the wall I had the system mounted on the wall and a little higher. Now with summer coming on I decided to try it mounted on the saw. Not real sure how it will work or how useful it will be but we will see. If it stays it will need a stiff leg to make the upright more sturdy.

Thanks for looking – now I need to get back to doing some fret cutting.

-- Just learning the craft my Lord and Savior Jesus Christ practiced.

6 comments so far

View melton22's profile


2 posts in 2040 days

#1 posted 03-20-2013 04:43 PM

Hi….Boy you got some system there. How well does it keep the dust out of the air? Danny :+}

-- Dan....Alabama....Scrollsaw Artist.... :+}

View ldl's profile


1135 posts in 2511 days

#2 posted 03-20-2013 05:03 PM

I have seen several designs for DC on the SS and I like this one also. It is going to be hard to choose between the designs when I do mine.

-- Dewayne in Bainbridge, Ga. - - No one can make you mad. Only you decide when you get mad - -

View Tennessee's profile


2880 posts in 2661 days

#3 posted 03-20-2013 06:11 PM

So if I am looking at this correctly, the clear vinyl removes the dust from the upstroke, and the nozzle underneath removes the downstroke. Very neat!
I also have one of those magnification lights, exactly like that,on mine, but I find that the lens tends to dust up over time from other things in the shop, and the lens itself is not true across its diameter, the magnification changes depending on where you look through it. I tend not to use it, but sometimes when doing tight pickguard work since I inlay my pickguards, I do use it with one eye closed.

-- Tsunami Guitars and Custom Woodworking, Cleveland, TN

View ralbuck's profile


5120 posts in 2413 days

#4 posted 03-21-2013 12:22 AM

As good of way s any other I have seen.

A have always thought that tools and patterns have 1 thing in common.

They both are a starting line for where you want to take them.

I have made modifcations on my 788 also. Still thinking about the best dust system; mostly use a small vac hose just wired under the table center. Not really good; but quick, easy to get out of the way and dose at least a fari job.

-- Wood rescue is good for the environment and me! just rjR

View eztrigger's profile


156 posts in 2074 days

#5 posted 03-21-2013 12:27 PM

you really went all out on that thing!

-- "Some get spiritual 'cause they see the light, and some 'cause they feel the heat." --Ray Wiley Hubbard

View jerrells's profile


918 posts in 3031 days

#6 posted 03-21-2013 04:11 PM

SO FAR, in about 4 hours of cutting, the system has proved to be 99% effective. The dust on top of the table is gone. There is a little dust under the table. I do not know if an adjustment will fix that or not. However, I am extreme satisfied with the vac. manifold so far.

-- Just learning the craft my Lord and Savior Jesus Christ practiced.

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