Saturday, May 21, 2016

DeWalt Scroll Saw DIY Utility Table from Charles Stopczynski

- I received an email from Charles a few days ago. He showed me a picture of a utility table that he and several members of his woodworking club have built for their DeWalt saws. I thought it was so interesting that I ask him to do a little write up so I could share it with all of you. I think the concept could be used to make something similar for other saws. Thanks Charles.

                                More pictures below the article.             


Many friends in the Gwinnett Woodworkers Association (Gwinnett County, GA)  and meself are scroll sawyers.  Most use the above saws.  Steve recently had an article on making of a tool for the top blade binding screw.  Seeing the photo of the tool it was clear to me there was no utility table.   I knew many scroll sawyers out there who have these saws could benefit from using one under their saw.  Having recently come over to the yellow side, and recently built a utility table, I decided to tell Steve about it.
Frankly, I was surprised that word hadn’t gotten around.  They’re great to catch little pieces of wood that fall from the cutting table, tools like your precious blade square, blades etc.  So, here goes.

The pattern for the utility table is right on your saw, the saw table itself is the basic pattern.  The table detaches very easily, remove the table locking knob, hold on, its cast iron and heavy.  Here is where you might want a second set of hands to help, also when re-installing it.  Don’t want to drop it $$*%$$$ ouch!   The screw that the knob attaches to might slip to the rear, just reach back and push forward when re-attaching, the table.  There is a washer in behind the knob as well.   (Note) you will need to be sure your table and blade is square before cutting.

Materials List:

         •     ¾” table material, about 24” x 36” such as plywood, MDF etc.
         •     3, 5/16 x 3” carriage bolts, 3 washers, 3 nuts, 2 acorn nuts (option)
         •     Approximately 80” of edge material, such as laminate, plastic, metal, Masonite®™ or other
         •     #4 x ¾” FH wood screws
         •      self-made tracer-spacer tool, ¼” scrap plywood, approximately 2” x 6” see photo.

Making a tracer spacer tool is easy.   Scribe a centerline lengthwise.   2” from one end drill a hole, just enough to accommodate a Sharpie®™ standard fine marker without wobble.

The material chosen for the saw table was a “sink cut-out”, which was already on hand.  It was from a household double kitchen sink, ¾” particle board with laminate on one surface about 24” x 36”.  Many other materials would also make a suitable table.  This particular design gives you a table that is wider than the saw table to catch falling objects, reasonable roomy, but not too big.   The design can be adjusted to suit your need.

Place the scroll saw table face down upon the laminate side and trace the outline of the curved parts of the table using the tracing-spacing tool and marker.   Decision time:  How much wider than the cutting table do you want your utility table.  I made mine 2” wider (on each side) therefore a total of 4” wider, hence the 2” setback on the tracer spacer tool.   I chose to continue the table all the way to the back of the saw stand.  This rear portion was made 10” wide, starting some distance forward of the rear of the table tracing.   A square was used, lines drawn from what would become the back of the table forward to meet the expanded outline of the saw table made with the tracer-spacer tool.  Here’s an opportunity make design changes to fit one’s need.  Cutting out the table while clamped to a workbench, a jig saw (heaven forbid) was used with a new blade suitable for cutting laminates, this particular blade cuts on the downstroke.  The result was a cut super clean.  Sand any irregularities.

Remove the saw from the stand, assuming you use the manufacturers saw stand.  In the rear center a 3/8” by 1” slot was cut to accommodate the rear bolt.  This was the starting point of mounting the utility table.  Place saw onto the sub-table.  Remember, here you have a decision to make as to front to rear placement of the sub-table.  I chose to make the front of my sub-table square with the front edge of the saw table.   The rear of the saw was first bolted into place, snug but not fully tight to allow left to right adjustment.   Use a square to adjust left to right sides measuring the distances on sub-table top to edges until centered, measurements were taken outward next to the front mounting holes for the saw.  Mark centers of the two front mounting holes.  Drill  a small pilot hole, then use a 3/8” drill to bore the two mounting holes.  No improvement would be complete without the mandatory trip to the hardware store.  The original mounting bolts you will now discover, are too short.   Use the 3, 5/16 x 3” Carriage bolts.

Washers to protect the saws finish and the casting itself were used.  Acorn nuts on top of the exposed threads in the front were added to save finger tips and finger nails from exposed thread edges.

Scrap laminate can be used to form the edge of the utility table, things tend tofind their way to the floor while sawing.  1/8” Masonite®™ was chosen for this table.   80” will be more than sufficient.  A 2” width was chosen for this particular table.  Once again it was learned that Masonite®™ bends some but it does not like tight bends.  The edging was installed using single piece covering most of the curved section. Two more short lengths down  each side and a 10 ¼” piece across the rear.  All edging was attached with #4 x ¾” countersunk wood screws.

This is the end of the daily posts. Keep scrolling for lot's more scrolls saw fun!

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The projects form these patterns can be sold without restrictions. The patterns cannot be sold.

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Wooden Vases on the Scroll Saw Book $12 Each
Each digital book is available for download immediately after payment.
The books are $12 per edition and contains eight unique patterns each.
Watch the following video to see how easy these beautiful scroll saw vases
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CATALOG DVD $20+ Shipping

- There are now two update DVDs for 2013 and 2014. The update DVDs contain just the patterns for that year and are available for $7.50 each. Order all three to have a complete collection.
Here is the link to the order page for all the DVDs.

This DVD contains all the patterns from the Scrollsaw Workshop blog from May 12, 2007 to December 2, 2012. There are 1113 pattern books many with multiple patterns. These are the patterns that are available in the free online catalog. This DVD is for those who wish to have all the patterns and don't wish to try and download hundreds of patterns. Use the DVD for club meetings, sharing with friends and customers, Archiving etc.

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This pattern book contains the following size patterns

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Stencil Printer 1.7

Stencil Printer Instruction Video.

The Scrollsaw Workshop Stencil Printer 1.7 is my latest software for creating patterns. It will create key chain fobs, desk name plates and more. Click the image above to download the latest version. It is free to use donationware. This software is for Windows PC only.

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Use the Scroll Saw Keychain Maker to start a small keychain business. Build yourself a nice display and make up severl keychains with common names. Sell at craft shows, on Ebay or at work. Everyone needs a keychain. Take custom orders. Heck just make them and give them away as gifts. It's all made easy with the Scroll Saw Keychain Maker. Watch the video demonstration then download the file below and get started with the fun.
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The Lifter

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Sue Mey Scroll saw artist

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Make sure you visit my good friend Sue. She is one of the finest scroll saw pattern designers in the world today. .

Philip Lowndes Noah's Arc Pattern Available. Watch the video below.

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Think Safety

Remember to keep the safety of yourself and others in your work shop in your thoughts at all times. Always wear eye and ear protection. Follow all the manufactures warnings that came with your power tools. If I demonstrate something on this web site that you don't feel is safe, don't do it. Your safety is your responsibility. Fingers are handy things, try to keep all of them.
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