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Table Saw Motor Tensioner Bracket Repair

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  • aametalmaster
    replied
    Mac i sent you a PM...Bob

    Leave a comment:


  • MAC702
    replied
    Originally posted by RichardParker View Post
    See that the motor is mounted very well, so it's shaft is parallel to the blade arbor shaft. If they are not parallel it can pull the pulley along the shaft.
    What is your experience in fixing motor mounts?

    Your post is cut-and-pasted from the first reply on the following website, without giving credit to its author or the site: https://www.finewoodworking.com/foru...igning-pulleys

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  • RichardParker
    replied
    See that the motor is mounted very well, so it's shaft is parallel to the blade arbor shaft. If they are not parallel it can pull the pulley along the shaft.

    Leave a comment:


  • Chris401
    replied
    I like seeing the old equipment repaired and put back to work.

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  • JamesReid
    replied
    Good job on this Don52, I reckon its better to strengthen the crack by drilling in the crack and a few spot welds.

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  • Tinker Joe 2
    replied
    Nice work, that took a while, that was really nice of you to do that, that for the photo's to show how it was done.

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  • Don52
    replied
    Originally posted by Metjunkie View Post
    Nice job Don, as always. Don't have any experience fiddling with die cast zinc stuff, but I'm wondering if heating the part, while straightening, would prevent, or lessen, any cracking.
    We did heat the part with a heat gun, so that it was hot to the touch. (about 150° F)

    -Don

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  • aametalmaster
    replied
    Nice fix. I loved making fixtures to do something right...Bob

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  • Metjunkie
    replied
    Nice job Don, as always. Don't have any experience fiddling with die cast zinc stuff, but I'm wondering if heating the part, while straightening, would prevent, or lessen, any cracking.

    Leave a comment:


  • Don52
    replied

    Originally posted by MAC702 View Post
    Did you get lucky on the threaded holes, or have to make a couple more?
    Yes, I was lucky. The threads were fine.

    -Don
    Last edited by Don52; 01-04-2020, 12:44 PM.

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  • MAC702
    replied
    Did you get lucky on the threaded holes, or have to make a couple more?

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  • Don52
    replied
    Once we installed the bracket we discovered that the cast iron frame of the saw as also bent. We were concerned that we would crack the cast iron if we attempted to straighten it out, so we added a wedge spacer to compensate for the bent surface. We also noticed that the belt was too long and rubbing on the guard so we made the wedge spacer thick enough to lift the belt off the guard. In the picture below you can see the wedge spacer above the die cast zinc bracket.

    10. Wedge added
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    And here is a closeup picture of the wedge.

    11. Wedge closeup
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    Next we installed the motor. In this picture the motor is hanging down and the belt is loose.

    12. Belt loose
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    We installed the belt.

    13. Belt tight
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    Here is the saw all done. We weren't too concerned with the tiny crack because it was on the compression side of bracket.

    14. All done
    Click image for larger version  Name:	14. All done.jpg Views:	0 Size:	65.9 KB ID:	605811
    Last edited by Don52; 01-04-2020, 07:54 AM.

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  • Don52
    replied
    One side of the bracket, which I labeled good, had two 45° offsets. The other side, which I labeled bad, had one 45° offset and one ba$tard angle. My first step was to straighten the bad side with the setup shown below.

    6 . Straightening setup
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    I applied force until I heard a slight tick sound, which was a very small crack in the upper right side of the bracket as shown below.

    7. Crack in upper right corner
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    Below is a close up of the crack in the corner.

    8. Close up of Crack.
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    The bracket was straighter but not entirely straight, so I decided to bend the good side to match the bad side. To accomplish this I put the straightening fixture in my arbor press as shown below.

    9. Bending the good side
    Click image for larger version  Name:	9. Bending the good side .jpg Views:	0 Size:	112.7 KB ID:	605805
    Last edited by Don52; 01-04-2020, 07:52 AM.

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  • Don52
    started a topic Table Saw Motor Tensioner Bracket Repair

    Table Saw Motor Tensioner Bracket Repair

    My customer stored his ancient table saw in the end of the garage in front of the car. One day his wife hit the motor of the saw with her car, when she was putting the car in the garage. It bent the zinc die cast bracket and it also bent the cast iron frame of the saw. The bracket is no longer available. In the first picture you can see the bent bracket.

    1. Bent bracket
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    I wanted to keep the base of the mounting feet of the bracket flat, so I built a fixture to support the bracket, while I straightened it. I used some scrap metal to build the fixture. One plate was 1-1/4" thick and the other was 1" thick so I used dual shield flux core wire to weld it, for high deposition rate and good penetration.

    2 . Straightening bracket
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    Below are some close up pictures of the welds on the bracket (because this is after all a welding forum).

    3. 1st and 2nd pass on fillet weld
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    4. Fillet Weld Done
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    5. Outside weld
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