SawStop Assembly

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Blog series by HappyHowie updated 05-28-2016 05:32 AM 9 parts 22946 reads 32 comments total

Part 1: First Step: To Stand the Cabinet Saw Upright...

04-25-2016 03:02 PM by HappyHowie | 2 comments »

I planned this purchase for a year. I got delivery this past Saturday. How can a single person lift and insert a heavy cabinet saw into a mobile base? Below is the method I used. Of course, I have a big advantage in this issue because of an overhead crane system I had installed in my garage back in 2009. This is one of those times where my electric overhead crane pays for itself. My brother Kyle watched his sons Kayleb and Chad and daughter Chanile hang the I-beam to the ceiling t...

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Part 2: Completed Saw Assembly

04-26-2016 04:52 AM by HappyHowie | 4 comments »

The industrial mobile base with a kit for the PCS saw arrived a couple days earlier than expected. I modified the mobile base so the professional cabinet saw would fit inside the base. Four boxes arrived just four days after I ordered my SawStop from I removed the accessories items packed inside the large box. Then I cut away the sides of the box so just the cabinet saw remained. Trimming away the bottom edges of the cardboard as well as the styrofoam allowed me to move the ...

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Part 3: Adjusted the Fence Rail

04-27-2016 01:44 AM by HappyHowie | 8 comments »

I discovered that my cast iron table top was not flush with the top of the extension table. The rip fence would bump into the cast iron table. It was obvious that I had not installed the rail correctly. This meant I had to remove the rail and loosen the bolts on the right side of the saw. This was a very tedious process. I went looking for an extra set of hands to help me. After several attempts I finally loosened enough bolts or screws to get the saw table top and the extension tab...

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Part 4: Crosscut Sled for Large Panels Completed

04-29-2016 03:11 AM by HappyHowie | 5 comments »

I should remember that there are no shortcuts to good work. It took longer to complete this sled build than it should have. I should have slowed down to get the countersinks drilled right the first time. Oh, well. The sled is done and is square. As I stated I used William Ng’s “5 Cuts to a Perfect Crosscut Sled”. It is just I took more than two sets of tests to get the front fence set to square. And so it goes.

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Part 5: Bob Van Dyke's Multi-Purpose Rip Fence JIG

05-07-2016 03:51 AM by HappyHowie | 7 comments »

Since I now have a new SawStop PCS table saw I have been looking for a good example or plan so I can make a universal rip fence JIG for cutting rabbets and tenons on my new table saw. Just this past week someone published on YouTube an old video that was used in a Fine Woodworking Magazine article published in December 2012. The article covered a rip fence JIG Bob Van Dyke designed for his SawStop’s rip fence. He bolts onto the JIG sacrificial boards for cutting rabbets and raised pa...

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Part 6: Making Van Dyke's RIP Fence JIG

05-15-2016 05:57 AM by HappyHowie | 0 comments »

I finally got some time today, Saturday, to work on this Rip Fence JIG. The trickiest part is done: the DADOes. The photo shows the dry fit. Before I glue these parts together I will drill the countersinks, holes, etc. I will start that tomorrow.

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Part 7: Overhead Dust Collection

05-19-2016 09:21 PM by HappyHowie | 1 comment »

I am surprised how much more sawdust is tossed on top of my new SawStop compared to my older contractor type Porter Cable table saw. I have also been disappointed with the lack of efficiency of dust collection I get from the optional overheard dust collector. I have read that some others have had the same poor experience; not everyone, but enough of us. Some have blamed the “T” connector to the main exhaust port instead of SawStop using a “Y” configuration. Also som...

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Part 8: My Adapted Solution for Overhead Dust Collection

05-22-2016 08:07 PM by HappyHowie | 2 comments »

I found bonesbr549’s post on his solution to optimize the overhead dust collection on his SawStop. I was going to attempt to apply his solution to my new SawStop. I went to my local Woodcraft store today in hopes I could find all the dust connector devices I would require. I got lucky. I can put all the parts together, but I will add a rubber connector for my SawStop 4” port. I will connect the 90 degree angle bend part shown below with that 4” rubber connector. The p...

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Part 9: Adding Rubber Cuffs Completes Overhead Dust Collection Setup

05-28-2016 05:32 AM by HappyHowie | 3 comments »

I received delivery this afternoon of the Woodcraft 4” rubber cuffs I ordered through I went right to work replacing the flexible hoses with this smaller and more rigid rubber cuffs. Since I also had a 2 1/2” rubber cuff handy, I replaced the small flexible hose taking off from the Y-adaptor. I faced that Y adaptor towards the dust collector Take a look at the before and after setup. Before 4” Rubber Cuffs After 4” Rubber Cuffs Installed The y...

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