|Project by onecarwallace||posted 10-23-2013 12:41 AM||2898 views||0 times favorited||5 comments|
A little backstory:
I’ve been learning to woodwork for a little over a year now and I’m just discovering my table saw’s limitations on my first real project. I’m building a shaker style nightstand and I’ve been having problems where I measure the distance from the fence to the blade and then the cut comes out too small. My table saw is a Bosch 4100. Yes, I know, it’s less than ideal for woodworking. Unfortunately it’s all I have room for in my 1 car garage. I’ll make the workshop a priority when I buy a new house some time down the road.
Anyway, I took a square to the fence and I found out that it is slightly off from perpendicular to the table. With the back of a square pressed against the fence, it rises 1/8” off the table surface at a distance of 6 inches from the fence. I guess that gives it an angle of 91.2 degrees. The other side is correspondingly 88.8 degrees off the table.
I called Bosch customer support and was amused to hear the guy tell me that if I want better accuracy than that, I should buy a Delta Unisaw. I appreciate his honesty but I was really hoping for them to send me a new fence. Anyway, I decided to fix the problem by building an auxiliary fence with set screws to correct the angle.
The fence has a t-track in it for 1/4-20 bolts, which I used two of to attach a piece of melamine. Next to each bolt I put two threaded inserts, which accepted set screws. The instructions for the threaded inserts said to drill a 9/32 hole. I don’t have that bit so I went one bigger with 5/16, and that still ended up tearing out the surface a little. That tear-out shouldn’t make a difference. Maybe I wouldn’t have gotten it with hardwood. Anyway, the last picture shows that I corrected the problem.
I’ve read about lots of problems with the Bosch 4100 TS fence alignment, both with being perpendicular to the table and parallel to the miter slots. Luckily I don’t seem to be having an issue with parallelism, but this fence can fix both problems. I think my next task will be to build one of these for the other side of the fence, and then make a new tenon jig since my current one won’t fit anymore.
Hopefully the next project I’ll be putting up here will be my shaker table.