Organic table saw fence / work bench

This is a story about modifications to a table saw to make it an even more useful tool. I find that it is the center of my workshop, both physically and emotionally. Unfortunately it also ends up being the workbench on too many occasions. This project seems to be organic, in that it starts in one direction, then grows in another direction as the requirements and materials change. Most of the parts for this have been salvaged or repurposed from some other parts. I did buy a spring clamp, and some welding rod. My welding skills are pretty poor, but I am getting better with a grinder to hide my flaws.

I am offering this more as a philosophy of what can be done, rather than a step by step what you should do. Feel free to take any of the ideas posted here and adapt them to your situation. You can give me hints on what I should do better or differently. Just don't comment on the general messiness of the shop.

Right now I know how large the project is. But it will probably grow, which it has already done. Subscribe to this thread so you will get future updates as they happen.

Step 1: Fence

I have a very nice 10 inch table saw.  The only problem is the fence. It has a nice arm, but the cast iron t-square/tightening mechanism is terrible. It may be cracked. It flexes. And the tightening cam is sloppy. Therefore accuracy is a relative term.

I would like a Besselmer (SP?) fence, but the cost is prohibitive. I started out by making the t-square. It is a couple of pieces of scrap 2” angle iron welded together at a 90 degree angle.  I bolted a piece of  3” square tube to the front of the table, offset a little so the t-square can ride on it. Exact instructions for this will depend on your individual saw/table combination. A piece of angle iron was added at the rear of the saw to support the rear of the fence.

Comments

[LynxSys]

Good ideas and a nice write-up! An amusing read too; I wish I could have been there for the square nuts incident. How well does the fence square itself when tightened down?

[vectorges]

The fence has a nice wide t-square on the front edge so it is very square. Take lots of time to line up the t-square when you weld it. Bolting would make it adjustable, bit it can also come out of alignment. IF you weld it out of square, you can add a shim to the edge of the steel fence, then cover with a piece of wood to get it perfect again.

[LynxSys]

Being a sub-par welder myself, I'd probably be inclined to bolt it and then weld it. What I actually meant to ask (and failed) was how well the design aligns itself to the table when you lock it tight. There are many commercial fences that are usually square, but are possible to lock down out of square if you're not careful.

[vectorges]

To paraphrase; The fence has a long t-square on the front so it aligns perfectly. I use a lever clamp with a spring in it so there is a little room for error on the pressure but it aligns very nicely. Better than the original.