Making the Saw Blade fit.

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Project by Karson posted 09-02-2008 10:40 PM 2924 views 0 times favorited 18 comments Add to Favorites Watch

You might have seen my workshop or some of my posts writing about my Table Saw. It’s a Fay-Egan 16” 5HP pussycat. It just sits in the middle of the floor and does it’s thing.

Feeding this monster can sometimes be a problem. The saw blades are not your standard blades. They are Commercial blades that are a lot heaver, thicker and expensive. If I see a blade that might fit, I buy it. I’ve bought a few at a machine rebuilders Roudolf Bass in NJ. They would buy entire plants going out of business and then rebuild the equipment and sell it. Their largest customer base was in South America.

Anyway they would hang on hooks in the back saw blades that came from tool rooms in these shops that they bought. I’d go through looking for 16” blades with 1 1/8” arbor hole. I picked up a few that way. I also picked up a couple that had 2” arbor holes, figuring some day I’d have a bushing made.

Well the day came today. I figured that I’d do it myself. I had bought a while back a small metal lathe and had not used it much at all. I went looking for bushing materials and I found it in some 3/4” washers that were case hardened #8. They had a 1 1/16 hole, a little small and a 2.5” outer diam.

I chucked it in the lathe and turned the center hole to 1 1/8” (Sorry no pictures). I then changed the chuck jaws and mounted the washer using the center hole to hold it.

I checked the hole a little later and the size was 2.004 not 2.010 as show in the picture.

I turned the washer down to the 2.004 size

I put the washer in the hole and tapped it flat with a hammer.

Fit like a glove or as if it was made for it.

The first one that I made had a blade hole size of 1.999 and the bushing was just a little loose. Didn’t want to fall out but could come out with sideways pressure on it. I used a center punch to put a dimple right beside the blade. I did that in three spots and it tightened it right up. Will not come out on it’s own.

So for $2.00 in washers (2 messed up because the hole was too big after my work) and 2 that fit. and 2 free saw blades that were given to the Mason Dixon Woodworkers by Sealy Mattresses when they closed up shop. I’ve got 2 great blades.

One rip blade and one triple chip blade that would be very expensive.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware soon moving to Virginia †

18 comments so far

View jm82435's profile


1283 posts in 2785 days

#1 posted 09-02-2008 11:03 PM

Great solution. Nice to see you are getting some use out of your metal lathe. :-) By the way, your pussycat looks like more like a tiger.

-- A thing of beauty is a joy forever...

View Dominic Vanacora's profile

Dominic Vanacora

508 posts in 2913 days

#2 posted 09-02-2008 11:22 PM

What a pain in the xxx. I know that those saws never stop working when we use them in a small shop. But you need to as you stated feed them with money sometimes. At least the blades last you a long long time and that give you time to look for more. Some time you need to climb over wall to get things done.
Nice idea.

-- Dominic, Trinity, Florida...Lets be safe out there.

View Quiglag's profile


9 posts in 2597 days

#3 posted 09-02-2008 11:37 PM

I always wanted a metal lathe. I would be making parts and pieces for everything.

-- Chris, Southern California,

View trifern's profile


8135 posts in 2811 days

#4 posted 09-02-2008 11:38 PM

Great solution Karson. Thanks for sharing.

-- My favorite piece is my last one, my best piece is my next one.

View Dick, & Barb Cain's profile

Dick, & Barb Cain

8693 posts in 3343 days

#5 posted 09-02-2008 11:49 PM

Thanks for sharing this with us Karson!

-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN.

View Grumpy's profile


20617 posts in 2894 days

#6 posted 09-02-2008 11:55 PM

Nice one Karson. I have done it the hard way on a drill & getting a good result is not easy.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View jockmike2's profile


10635 posts in 3290 days

#7 posted 09-03-2008 12:06 AM

Good for you Karson, I run into that problem when I bought that old lathe off my buddy up at Houghton Lake, the thing was niegh on to 100 yrs old and even the bearing for it I had to get special ordered. By the way thanks a ton for the heads up on the leads for my lathe. It only took a year but I finally got a DC module from one of those places you gave me and they finally got it in. I got the motor rebuilt too. So I basically I have a new Delta 46-755X Lathe. It runs with a whisper thanks to you old buddy. I made my daughter a bowl for her birthday and a posterI framed of Brett Farvre that was 30 X 20 in. She loved them both. Pretty hard getting used to the lathe ,it aint like falling off a bike. Thanks again.

-- (You just have to please the man in the Mirror) Mike from Michigan -

View TedM's profile


2002 posts in 2776 days

#8 posted 09-03-2008 12:06 AM

A cool fix! Kudos!

-- I'm a wood magician... I can turn fine lumber into firewood before your very eyes! - Please visit and sign up for my project updates!

View Bob #2's profile

Bob #2

3809 posts in 3065 days

#9 posted 09-03-2008 01:06 AM

Karson, you did a good thing here!
I think you have rekindled my jonesing for a metal lathe again.
It’s almost a necessity for those of us that play on the periphery of wood working. We always seem to need something that is just a few minutes away or a hundred dollars over budget. :-)


-- A mind, like a home, is furnished by its owner

View Karson's profile


34987 posts in 3444 days

#10 posted 09-03-2008 01:13 AM

I would also like a milling machine. I was in a wood shop where the owner used a metal milling machine to cut the tenons on the pieces of wood.

Talk about cool. Makes me want to have one.

I guy that help me move my table saw from where I bought it to my home. He had a home with a drive in basement and he had big lathes, milling machines, saws and he would rebuild a piece of junk into a full functioning machine.

He was also not married.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware soon moving to Virginia †

View Karson's profile


34987 posts in 3444 days

#11 posted 09-03-2008 01:18 AM

I’m glad that I tried this. I almost went over to a friend that has a Sherline Lathe and cut it there. But, I found out that my lathe had both jaws for inside and outside holding. It’s nice to find the parts for it.

I finally got the carbide cutting pieces this week. I originally ordered 3/8 but they were too big. (anyone need 3/8” carbide cutters?) I had picked up some 1/4” ones a while ago and they didn’t work. so I finally bought some 5/16” cutters They work great.

Now its a matter of figuring out how to cut efficiently.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware soon moving to Virginia †

View Dan'um Style's profile

Dan'um Style

14001 posts in 3026 days

#12 posted 09-03-2008 04:45 AM

great posting. fun read. I like your solution. Years ago, I worked at a factory with a machinist that had a european table saw. He had the other problem where the i.d. of the saw blades were too small. His solution was to jig-grind them on a Moore Jig-Grinder (on third shift).

-- keeping myself entertained ... Humor and fun lubricate the brain

View Karson's profile


34987 posts in 3444 days

#13 posted 09-03-2008 05:25 AM


That is some machine. Would be nice to own one of them also.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware soon moving to Virginia †

View SawdustMill's profile


58 posts in 2776 days

#14 posted 09-03-2008 05:43 PM

Whew, just hearing about that saw makes my amateur fingers hurt :)

View Lee A. Jesberger's profile

Lee A. Jesberger

6792 posts in 3023 days

#15 posted 09-07-2008 02:42 PM

Hi Karson,

Great idea! Glad to see you finally got to use that lathe.

I hope the arbor washer is bigger than the turned washer.

You didn’t mention how long that blade keeps spinning after you shut off the saw. I know we timed it, but I can’t remember the time.

As I recall, you have time for a lunch break while waiting though. lol


-- by Lee A. Jesberger

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