I recently purchased a Makita chop saw at a garage sale for next to nothing and it had a problem with the switch and was missing most of the vice. You can see in the first picture the condition the saw was. It was completely missing the screw the handle and one jaw and the anchor block for the vice. When I got it home first thing I did was fix the switch which was relatively easy to do I then took the plastic hand wheel off my bandsaw and used it as a pattern to cast one for this. You can see the pattern in the second picture along with a jar of clay I used to fill the hole in the middle of the had wheel and the tape to put over the hole. Hand wheels are real easy to cast. You do have to cope down to the Parting line which takes a little bit of skill because they are not flat but they're completely round in profile so they draw very nicely. In the third picture you can see the two bits of metal I found in my pile of crap along with a piece of all-thread rod that formed the basis for the raw materials for the repair. The fourth photo shows the mold after I poured it, you can see my foundry furnace behind the mold. The 5th photo shows the rough casting of the hand wheel. [Next to it is another casting for a different project]. Note that my sand is good enough that you can even see in the casting the piece of tape that I used to cover the hole in the middle of the wheel. In the sixth photo you can see all of the parts together....the threaded rod, the Jaw support, the bearing through which the threaded rod goes, all the washers nuts and the handwheel. It was quite a learning effort to make these threads on the various parts. I would not have been able to make this part so accurately on my old lathe. In the seventh photo you can see the threads on the Vise Jaw support and the hole into which the threatened Rod fits. Note the split pin inserted through. Of all the operations in this project, drilling that hole was probably the most difficult because it was not drilled through the center of the round piece it was drilled slightly off-center which is a difficult hole to drill especially with a 1/8" Inch drill bit. I also managed to drill it accurately enough that the split pin can be seen through the hole. This split pain rides in the groove on the end of the threaded rod and allows the rod to draw the Vise Jaw backwards when you unscrew it. 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Nice job of resurrecting the dead. But good golly, put some carriage returns in those long paragraphs. It make my eyes twitch trying to read that.
Nice work, I'd be inclined to invest in a new disk, that one looks pretty clapped out and you have no idea what abuse the previous owner put it through, just a thought.
Great suggestion....this was originally a Facistbook post so I just copied it over. I am usually more focused on making things readable but on their format the paragraphs take up space. You suggestion is noted.
