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Project Information

April 7, 2015

UPDATE: Drawings added to end of post for those who have this switch on their Unisaw.

Here is my original switch for my Unisaw.



To increase the safety factor on my tablesaw, I decided to add a "paddle" safety switch to my Delta Unisaw.

It's a relatively simple solution.

PARTS:

3 - pieces of wood

(2) Sides = 3 X 7 X 3/4 inches

(1) Paddle = 5-1/8 X 7 X 3/4 inches

2 - 1/4 inch all thread rods 5-3/4 inches long
4 - nuts
4 - washers
2 - metal rods 1-1/2 inches long



SIDES:

Before the left and right sides were cut to shape, 1/4 inch holes for the all thread rod and the pivot holes were drilled while the pieces were held on the drill press together.

Then the Left and right hand shapes were cut.

PADDLE SWITCH:

After cutting the paddle to shape a hole for access for the start button was drilled.

A recess in the area of the stop button was drilled in the back of the paddle.

Two holes for the 2 metal pivot rods were drilled and the rods inserted.

I decorating the front with my wood burning tool.

All edges on all wood parts were rounded over. Danish oil was used on all wood parts.

The paddle is now ready.



The recess for the STOP button was made so that the paddle could be positioned closer to the switch housing and the START button would be closer to the surface of the paddle. I'm estimating that 1/4 inch movement is all that's required to activate the STOP button.

The parts are then assembled loosely …



… and slipped over the switch housing.



The side pieces are 1-1/2 inches longer than the sides of the original switch housing. When the all thread rods are installed, the design allows for UP and DOWN as well as IN and OUT movement on the original switch housing to make positioning the paddle switch easy.

After the hole in the paddle is centered over the START button by moving the assembly UP or DOWN, the assembly is then moved IN or OUT on the switch housing till the paddle hangs properly. The nuts are then tightened on the all-thread rods … tight enough so that the safety paddle switch doesn't move.

The original switch box was not harmed in this installation.



Now I have a bigger target to shoot for if I need to shut the tablesaw off in a hurry.

Thanks for looking. Comments and questions welcomed.

DRAWINGS:

The following is an experiment. I've included SU drawings of the parts. Please let me know if they are useful. If not I will remove them from this post.



LEFT SIDE



RIGHT SIDE



PADDLE LAYOUT



PADDLE PIVOT HOLES



PADDLE RECESS HOLE

End of experiment.

Please leave a comment and let me know if the drawings are helpful. Thanks.

Gallery

Comments

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4,507 Posts
clever you Americans!!
 

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822 Posts
Well done and an intelligent safety upgrade.
 

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5,738 Posts
Very cool!
 

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375 Posts
What a great safety upgrade. I am saving this one!!!
 

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192 Posts
With you 100% great safety upgrade
 

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657 Posts
That's great. Scrap wood and some hardware. Just as good as the ones in the store.
 

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682 Posts
Nice work Alex. I'm wondering what you are doing that you need to shut the saw off so fast for? LOL
 

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110 Posts
Hah! Looks a thousand times better than the original!
And works better too. You clever Americans!
 

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4,010 Posts
you did a really nice job on this, i think all saws should come with a device such as this…
 

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818 Posts
That's a nice setup you made Alex looks real professional .
I made one not as fancy a couple years ago and have only one problem with it when I lean forward at times my thigh will push the paddle and shut off the saw during a cut .
It sure is a handy safety device that got me out of trouble a few times .

Klaus .
 

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1,332 Posts
Very nice idea. Thanks.
 

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668 Posts
A very useful accessory, been meaning to make one for years.
 

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7,008 Posts
Very GOOD!

A Nice & Easy way of mounting the device too!!

COOL!

Thank you!
 

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6,114 Posts
Really fine and really clever.
Play safe or die trying.
Best thoughts,
Mads
 

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Hi All

Thanks for all the comments and looks.

Kiefer .. with the original switch I would also occasionally hit the stop button accidentally. There were other times when I would be searching with my leg trying to find it. Now it's going to be easy to find. I hope I don't accidentally turn it off too often

Dr. Ken .. there are times when you are ripping some wood and your two hands are holding the board and it starts to close up and pinch the blade. Thats when you need to turn the saw off and still control the board.
 

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211 Posts
Darn you Alex, now I have to add another project to my 'Shop Improvements" list. I too have a Unisaw and that definitely needs to be added as soon as practical. All kidding aside that is a great and highly practical project for enhancing shop safety. I really appreciate your sharing it with all of us. Well done!
 

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Alex, if you are finding the wood pinching the blade you need to think about a Riving knife, assuming your saw can take one of course.

I had a kick back about a year ago. I knew it was coming, tried to take my hand away but it caught me just above the knuckle tearing a hole in my hand. I almost past out with the pain. Since then the riving knife has gone on and only comes off when using a dado set
 

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2,584 Posts
You can't beat an idea like this. Very cleaver set up. 5 stars for safety on this.
 

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Great looking upgrade, Alex! One of these has been on my To Do List for way too long. Gotta get 'er done! Thanks for sharing.
 
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