Reply by Kenny

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Posted on Dewalt 876 Bandsaw, it was all going so well..... can this be fixed?

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260 posts in 2447 days

#1 posted 03-29-2012 07:09 PM

It’s not so bad buddy, there are ways to fix this! No reason to fret.

There are a few ways to go about this. The method I used on a scroll saw of mine and my buddies bandsaw is a very permanent method, though there are others that are more temporary.

The easiest solution is to add a new top over the existing top using a piece of phenolic coated plywood. Simply use machine screws in counter-sunk holes to bolt it right down. You can mill yourself a new miter slot in the ply if you choose as well. It’s best to shim under the ply where the table dips, this will keep the ply from sagging.
The only downfall, is you lose a bit of resaw capacity.

What I did for myself and my buddy, was to use Devcon’s Liquid Aluminum and Aluminum Putty and built the table back up to level. You could also use a product like USC’s All-Metal body filler. You will need to scuff your table well with 100-150 grit paper to assure good adhesion. Then build the lows up using the putty and skim-coat the entire table-top with the liquid.

Now, once the Devcon has dried, use a long, flat sanding block to level the surface so it’s dead flat.

Now, you will have a solid and dead-flat table top that isn’t going anywhere.

You could also fill the lows with Devcon and then add the phenolic coated ply over this. Or you could substitute a piece of aluminum plate 1/8” to 1/4” thick, obviously leaving the miter-slot exposed.

There are many ways to fix this. But I would advise against trying to pound the table flat in any way. Aluminum is brittle and may crack.

Good luck.

-- Kenny

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