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Old 09-29-2016, 12:44 PM   #286
Clodfobble
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ALSO DID YOU KNOW... in the movie Spy Kids, the bad guy's henchmen were called Thumb-Thumbs.
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Old 09-29-2016, 03:28 PM   #287
Gravdigr
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Well, that's thumbthing.
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Old 10-01-2016, 04:14 PM   #288
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Sawdust?
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Old 10-01-2016, 07:13 PM   #289
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He's a god
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Old 10-17-2016, 11:43 AM   #290
glatt
 
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Quote:
Originally Posted by footfootfoot View Post
Fuck that shit, it's thumb jokes until he gets his lazy ass down to the shop and starts building that cover that he is avoiding.
I did a little work a few weeks ago and need to update this thread. It's slow going though, because I'm running in to problems again where the plans don't match my saw as built. And I have trouble visualizing the piece I'm making and how it fits with the saw until after I have made the piece and it doesn't fit. Then I can see what needed to be wider or longer, or whatever.
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Old 10-17-2016, 01:11 PM   #291
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Back at the beginning of the month on October 2nd, I dug around for a nice scrap of quarter inch plywood to serve as the most visible part of the saw. The upper wheel cover. It will feel good to have this cover in place because that big spinning wheel of death is just a couple of inches from my nose as I use the saw.

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I cut it to shape on the table saw except for the very last inch or two of the inside corner. For that, I went over to my BANDSAW to cut it out.

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I cut the first simple edge board to length and glued it in place

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The next edge board has a little notch cut out of it to make space for the blade guide, which slides up and down.

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Old 10-17-2016, 01:15 PM   #292
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More edges glued up.

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This is a complicated piece to fit around the different layers of the frame.

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Glue up

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These diagonal pieces need to have a bird's mouth joint cut into them to help hold the corners together. A band saw is the perfect tool to cut those, and I just happen to have one.

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Old 10-17-2016, 01:19 PM   #293
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Gluing up some more

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Laying out the lines for the rear plywood piece. This has to fit over the wheel and axle, so has notches cut out of it. I cut it out on the band saw.

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The motor was hanging off the end of the shelf. I guess the plans were designed for a different motor shape. I needed to extend the length of the shelf.

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and here you can see that I have changed the pulley to slow the blade speed down to the speed I want. So you can add $10 to the cost. I still need to actually bolt the motor down, but first I want to finish any tuning I need to do of the saw.

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Last edited by glatt; 10-17-2016 at 02:17 PM.
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Old 10-17-2016, 01:24 PM   #294
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The next weekend, I clamped the cover in place to test the fit. It doesn't fit. It rubs in at least two places. Sigh. At least it looks good.

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The oil can blade guard is too close to the cover. I think this is because I made the wheels slightly larger than the plans called for so this would be a true 16 inch band saw.

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So I take the cover to the drill press to hog out some material. I need to remove enough material while still leaving enough to provide strength.

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The material is removed. The blade guard doesn't rub now.

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Old 10-17-2016, 02:00 PM   #295
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You should have been a documentarian.
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Old 10-17-2016, 02:05 PM   #296
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The cover is held in place with little tabs that fit into holes drilled in the frame. I tapered the dowel part of these tabs, and then located the correct placement for them.

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The tabs glued in place.

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And checking the fit, they are too close together to fit around the leaf springs.

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So I trim them both with a hand saw and remove the waste with a chisel.

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Old 10-17-2016, 02:15 PM   #297
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And I test the fit again. I can get the thing around the wheel without obstructions. Nothing is rubbing! But the tabs don't reach deep enough in the frame. I think it's a metric vs. inch thing. My frame is made of 3/4 inch boards. Who knows what Matthias used in Canada? I don't. But I need to get about 3/16th of an inch closer and I can't.

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I need to cut these notches in the cover sides deeper. But then it won't fit over the wheel any more. The front of the cover will hit the front of the wheel. It won't be deep enough. So I think I'll need to cut some strips to glue to the edge of the cover to give me the depth I need, and then cut the notches deeper.

So that's where I am. I haven't touched this project in 8 days.

It's almost to the point that I'm considering just building the cover over from scratch again instead of trying to shim my way to a good fit. But I used my best scrap of plywood, and it looks so nice.
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Old 10-18-2016, 06:27 AM   #298
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If it were me I'd cob it and slap a coat of paint on the offending area, but it wouldn't bug me every time I used it.
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Old 10-18-2016, 05:13 PM   #299
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is it that the plywood needs to move to the left in your photo, or the peg needs to move to the left, or both?
In either case I'd just rip a few strips of 3/16" thick material off a 1x and glue that to either the ply or the frame.

Probably a metric/standard issue. Metric ply is a shade larger than 1/4, 3/8. or 1/2 and standard ply is a shade under 1/4, 3/8, 1/2" etc. Not sure it would add up to 3/16" though. Probably it's the nut behind the wrench...
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Old 10-18-2016, 06:17 PM   #300
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Mostly the peg needs to move to the left. I'm gonna make new thicker peg things that reach further over so they have some meat to dig into.

Tempted to go down there tonight, but that glass of wine I had earlier makes power tools a bad idea. I may just catch up on Stranger Things.

My dad is coming to visit in early December and I'd like a basically finished saw then. Time's ticking.
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