SawStop #3: The Assembly, Phase 1

  • Advertise with us
Blog entry by Don posted 04-03-2010 05:16 PM 2782 reads 0 times favorited 8 comments Add to Favorites Watch
« Part 2: Unpacking Part 3 of SawStop series Part 4: The Assembly, Phase 2 »

Last night I got the main part of the saw assembled including the extension wings, rails, and extension table.

Getting the extension wings on by myself was a bit tricky. They are really heavy and I had to hold them up with one hand and get the bolts threaded with the other. I almost asked my wife to come help but then I remembered the last time she helped me in the shop. (Good thing she doesn’t read my blogs :) )

If anyone else does this, do not put the motor cover on when the instructions say to. It gets in the way of bolting down the wing and can easily be put on later.

More impressions:
The insert is really well designed. It’s a solid half inch thick, unlike the sheet metal insert that came with my General saw. It should be real easy to make my own zero clearence inserts with the way this is designed. I especially like the bracket that is used to remove the insert and to lock it in place.


The inside of the saw is also really well designed. I’m not a mechanic by any stretch of the imagination so I’m really qualified to asses something like this but the parts all look a whole lot beefier than anything in my General saw. And the way the dust hose is a solid connection straight to the thing that wraps the blade (whatever it’s called) looks like there will be virtually no sawdust going into the cabinet. When the blade is set to 90 degrees, the motor is almost completley out of the cabinet which should reduce the amount of dust getting onto the motor and if I ever do have to do any repairs they should be real easy.


The extension table looks a little flimsy when you see it upside down. It’s only a 5/8 inch top with 1 1/2 inch pine ribs. It would be a whole lot beefier had I built my own. It feels much stronger than it looks though so we’ll just have to wait and see how well it holds up. It does have levelers on the legs though!

Here’s the whole saw so far. The unblemeshed cast iron top is really a site to see. I think it only took me a few weeks to accidentally drag a screw across my general saw top and put a nice scratch in it. I hope this one lasts a little longer:


-- Don - I wood work if I could. Redmond WA.

8 comments so far

View GaryK's profile


10262 posts in 5483 days

#1 posted 04-03-2010 05:38 PM

Nice! It looks like you’ll be making some sawdust soon.

Can you take a picture of the electrical plug that it came with? Something closer.

-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX

View JJohnston's profile


1622 posts in 4786 days

#2 posted 04-03-2010 05:39 PM

What does the underside of the insert look like? The one on my industrial model has some complicated machining, probably relief for the arbor bearing and washer. This is why I haven’t made my own yet:

-- "A man may conduct himself well in both adversity and good fortune, but if you want to test his character, give him power." - Abraham Lincoln

View patron's profile


13722 posts in 4835 days

#3 posted 04-03-2010 05:58 PM

well done ,

sure looks like a great upgrade .

enjoy !

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View Don's profile


517 posts in 4567 days

#4 posted 04-03-2010 06:16 PM

I guess I didn’t look very closely at the bottom of the insert. It may not be as easy to make my own as I thought. Here’s a shot of the bottom of the insert and one of the plug:



-- Don - I wood work if I could. Redmond WA.

View Dennisgrosen's profile


10880 posts in 4610 days

#5 posted 04-03-2010 06:20 PM

it realy looks great sofare
ceep let them coming
you do a fine toturial
on this


View Kent Shepherd's profile

Kent Shepherd

2718 posts in 4781 days

#6 posted 04-03-2010 06:39 PM

Having assembled multiple saws of different brands the last three years, I was amazed at the ease of assembly of the Saw Stop, down to the organization of the bolts. The fit and finish of the saw is definetly superior to other saws I’ve seen. Even if you take away the safety factor, I believe this is a better saw than most of what you see today, unless you get into the really industrial relm at a much higher price.

Thanks for the blog on your experience.


View Scott Bryan's profile

Scott Bryan

27248 posts in 5316 days

#7 posted 04-03-2010 06:43 PM

Don, this is a nice blog and I am sure you are ready to make some sawdust. I have to agree that making your own zero clearance plate is going to be a challenge. If memory serves me right I think they are $29.00 apiece. For this price I would just simply buy one.

-- Challenges are what make life interesting; overcoming them is what makes life meaningful- Joshua Marine

View Brad_Nailor's profile


2545 posts in 5452 days

#8 posted 04-03-2010 09:16 PM

That saw looks like it’s almost ready to cut some hot dogs! I love my Unisaw allot…but I would trade it in a second for a Saw Stop of equal size and fence..


Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics