Table Saw Rebuild

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Project by Eric posted 11-02-2013 05:45 AM 4055 views 8 times favorited 10 comments Add to Favorites Watch

I had bought a cheaper table saw a few years ago and I hated the thing since I bought it. It never lined up square, the tabs in the guides prevented me from making any sleds, and I had to use it quite often. All in all I hated it the most and it was the tool I used the most.

I was fed up with it and pondered for a while on how I could improve it. I really wanted to buy a new one but just didn’t have the funds. So seeing how the saw sucked anyways it wouldn’t hurt to try and improve it.

I glued 1/8” hardboard to a 1/4” piece of MDF. I then bolted it to the existing table making sure the front edge was perfectly square to the blade. Routed out 3/4” rails square to the blade and and made a temporary fence and kabam! A nice square saw. I couldn’t believe how easy it was. Unfortunately I wanted to remove the existing table and just replace it but there was to many brackets and tabs and all sorts of crap to deal with so I opted to loose 3/8” of blade height to avoid all the hassle. I don’t mind.

I loved the saw so much I decided to make a stand for it. I also added a fold out outfeed table and to free up space I put attached my router table to the side in the same manner. They both have retractable legs that fold up up the tables when they fold down. I then built a new fence with the help of Matthias Wandel’s design.
I also put it on retractable caster wheels so it can be moved around easily if need may be.

If anybody has any tips on how to cut out for the faceplate please let me know. I don’t think I want to use a jig saw for I want a nice clean cut. Maybe a jig set up for the router? Of course I would have to remove the table to do so. Any suggestions would be appreciated.

It is now the best tool that I have and am very proud of the outcome. Attached is a video that I posted on YouTube.

-- Eric the "Fabbrocator" Fabbro

10 comments so far

View hoss12992's profile


4068 posts in 2043 days

#1 posted 11-02-2013 05:57 AM

Great job and very inventive. Welcome to LJ’s

-- The Old Rednek Workshop

View Eric 's profile


35 posts in 1828 days

#2 posted 11-02-2013 06:04 AM

Thank you very much.

-- Eric the "Fabbrocator" Fabbro

View FatGuyinaLiitleShop's profile


19 posts in 3282 days

#3 posted 11-02-2013 06:18 AM

They say there’s no wrong way to eat a Reese’s…......

View Ted78's profile


401 posts in 2150 days

#4 posted 11-02-2013 07:41 AM

I feel your pain with having hated your table saw. I’ve got cheaper 80’s Craftsman saw. I could almost deal with the cheap plastic, tin and aluminum it’s made out of, but why they felt the need to re-invent the wheel on every little aspect of it drove me nuts, everything from the fence and molded to the table, trapezoid rails, and weird tabbed faceplate to goofy, useless anti kick back pawls made of stamped tin, and shallow grooves cut all across the top of the table I couldn’t stand. Your solution would have fixed almost all my gripes about it, but I finally acquired an old 60’s Detla Homecraft saw. Still not a professional saw by any stretch but the simplicity and standard design make it easy to adjust and build jigs for. My only complaint is that it is a 9” and not 10” saw. I don’t miss the extra inch at all, but blades are harder to come by.
Nice Job on the re-build. Just looking at the pics of the clean, flat, simple, built to function, not to look frilly in a showroom makes me happy.

-- Ted

View Eric 's profile


35 posts in 1828 days

#5 posted 11-02-2013 08:58 AM

thank yo very much for the comment

-- Eric the "Fabbrocator" Fabbro

View Boxguy's profile


2741 posts in 2417 days

#6 posted 11-02-2013 10:34 AM

Eric, I like your tablesaw rebuild project. I had a Bosch router table with many of the same problems. It was maddening. I solved it with a piece of recycled counter top from the local Habitat restore.

You do need a faceplate, but why make it conventional? What if it were square or diamond shaped? If the insert were on an angle to the feed of the boards it would be less likely to snag on the edge of the insert. All you need to do is cut a hole in your top and make up some more of the top material of the same board and laminate material to make inserts out of. I would make plenty of extra insert blanks while I was at it and just hang them on the saw for some time down the road.

All that counts is that the top and the insert are the same thickness. You could make an insert for 90, 22 1/2, 45 degrees and another for a dado set up. It would probably help the process if you took time to blow out any sawdust that was in the hole before you dropped in the insert. The best of all solutions would be a screw or bolt that would thread into the original top below your new table. That way you could secure the insert in place and keep from bumping it out of place with sliding boards.

Welcome to lumberjocks. Have fun. Contact me if I can help you, or have not made this clear. By the way this is an alternate way of making a lid and mortising in a piano hinge in a box. Keep boxing and keep posting.

-- Big Al in IN

View Oldtool's profile


2724 posts in 2340 days

#7 posted 11-02-2013 11:10 AM

Nice saw improvement, well designed, most impressive. Enjoy.

-- "I am a firm believer in the people. If given the truth, they can be depended upon to meet any national crisis. The point is to bring them the real facts." - Abraham Lincoln

View majuvla's profile


13071 posts in 3017 days

#8 posted 11-02-2013 12:35 PM

Beautiful solution of the problem. Sometimes ’’do it yourself’’ is better than bought original.

-- Ivan, Croatia, Wooddicted

View kaerlighedsbamsen's profile


1251 posts in 1863 days

#9 posted 11-02-2013 01:20 PM

Love it when people fix stuff instead of goving up on it. Thanks a lot for sharing!

-- "Do or Do not. There is no try." - Yoda

View ccopes75's profile


14 posts in 2165 days

#10 posted 11-02-2013 03:38 PM

Great job with your saw. I have pretty much the same saw with the same problems and am looking to do a similar conversion to it. I, like you, saw Matthias’ fence and plan on using it as well. Thanks for sharing!

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