Need help aligning table saw

Alan -

I had a similar issue with another brand contractor’s saw, and the ultimate solution was complete dissassembly of the saw and drifting the trunnion slot holes with a rat tail file. (I couldn’t get my saw any closer than about 0.015 before, after the modification I have the alignment at 0.002.)

I assume you removed the trunnion bolt washers before you installed the PALs kit. If you didn’t that could be the problem as the original washers may be hanging up in the slots.

I wrote a paper on everything I went through with photos. If you want to see it, send me a PM with your email address.

-- Joe

i went through a similar issue aligining my delta contractor. one thing that helps is pick up a 10 inch abrasive wheel and use that as the alignment blade. is is more uniform all around and worked great for me. good luck

-- 20 year old new woodworker. advice and tools much appreciated.

Alan – Assuming this saw has connecting rods, it’s possible that the rods have twisted within the brackets and are causing this problem. To check that, set the blade at 90 degrees and lay something perfectly flat (like a small pane of glass) across the rods….if the plate rocks, the rods need to be loosened and adjusted before you can align the trunion brackets.

Elongating the holes is another possibility of the alignment is really whacked. It’s possible it’s been that way since the saw was new. If you go to that much trouble, make sure the mating surfaces between the table and brackets are smooth and flat, and you might as well upgrade the bolts and washers to a better grade of steel while you’re at it…at least that way you’ll be eliminating possible alignment causes down the road.

Knotscott is right about replacing the bolts.

I replaced mine with studs and used threadlocker to hold them in place. That removes any wear and tear and the table top threads – which if stripped will cause great grief.

-- Joe

Anybody want to buy a powermatic 64 with stripped threads in the table. No. 5 bolts ripped the threads right out…but the zine bolts would not tighten.
I think it’s time to buy a R4511 so I can saw wood and not rebuild saws. Good Luck.

-- Round tuit's don't do it, just get a round toit, avaiable where buckets of steam are sold.

You can see if the table top can be twisted any. I’m not sure how it’s attached, but if there’s some room for adjustment that way, you might look into it. Just a thought.

-- "At its best, life is completely unpredictable." - Christopher Walken

I had a Jet contractor-sthyle saw and the trunnions are mounted directly to the table (as are most saws in this class) so that would eliminate moving the table itself.
I have heard of people elongating the holes in the trunnion slightly to get the blade aligned correctly. If you are out by a full 1/16” over the length of the blade that would mean that a bit over 1/32” on each trunnion should give you enough room with a little fudge factor as well.
Also, make sure that you are measuring it correctly and accurately. I have seen a few saws that the owners had gotten some comfusing instructions on measuring this alignment. We later found on each of them that it was much closer than they thought. Sometimes taking a day off and coming back at it with fresh eyes helps a bunch.

-- Tom Hintz, www.newwoodworker.com

Makinsawdust:
FYI – the stripped out holes in your saw table top can be fixed with Helicoils.

-- Joe

If you decide to remove the trunnion assembly from the table, it’ll be easier if you have someone help you turn the entire saw upside down so you’re not fighting gravity. I once overloosened the bolts on my contractor’s saw, just enough to allow the the trunnion assembly to fall out of the brackets. I ended up having to turn the saw over, by myself, to get it back together. If you do turn it over, pick it up – don’t let the weight of the saw rest on the legs as it’s going over, or as you right it.

-- Measure twice, then try to figure out which one was right.

The following post on my website can provide with complet table saw tune up instructions including alignment http://www.woodworkingtipsandtools.com/2009/02/15/table-saw-tune-up/

-- drbob at http://www.Woodworkingtipsandtools.com