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Pin Router for a Sears Radial Arm Saw

Pin Router for a Sears Radial Arm Saw
There are times when a pin router would be handy, and a radial arm saw provides a handy platform with its arm adjustable for height and the motor carriage that can be locked at any position along the arm. And, if necessary, the motor can be tilted for very special needs.

Some radial arm saws, like Sawsmith and Montgomery Ward's Powr-Kraft, came from the factory with a high-speed spindle on the right end of the motor for a router collet chuck.  The Sears radial arm saws have a spindle with 1/2 inch thread for a Jacob's Chuck.  The Sears spindle runs too slowly for use with a router bit. 

 
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Step 1Mounting holes

Mounting holes
This Sears radial arm saw came with two threaded holes on the bottom of the motor.  The holes were used to secure the motor in the crate for shipping.  The holes are 5/16 inch by 18 threads per inch.   
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35 comments
Jan 7, 2010. 10:33 AMGrumpyOldGoat says:
HEY!!!

THANKS for simplifying my life!

I have an 8 1/4" and a 10", both Sears.  One is going to be dedicated to 'other projects' now.
Jan 7, 2010. 2:36 PMGrumpyOldGoat says:
The 10" is a new acquisition from habitat for Humanity for $35.  It has some serious problems. The elevation crank is gone, the yoke that disengages the miter is broken.  The power cord didn't quite get pulled far enough out of the way at least once.
It lived outdoors for quite some time as well.  The table top is shot.
I can build an adapter for a small router and make if single purpose until I find the parts to fix it right.
All the swivel and tilt parts seem tight, as well as the carriage track.
I have a 10" slide miter too, but the radial arm is so much easier for some projects.
They DO require care and caution when in use though, and not for the careless types.
Jan 7, 2010. 9:08 PMGrumpyOldGoat says:
I found a link on www.lumberjocks.com.

A very good site for woodworking tips, tricks, and very talented people willing to help.

Sort of a woodworkers instructables site.
Jan 8, 2010. 6:34 AMGrumpyOldGoat says:
I failed to mention that the link I posted  was where I found a PDF of the manual.
Manuals are written by the engineers that designed them.
The manufacturers should follow up with a new manual that has USERS notes included on the best, easiest, safest manner to use their product.
Lumberjocks.com is like an online users manual for any woodworking question.  From how to sharpen a chisel to how to keep body parts in their original, attached, condition when working with power tools.
Dec 23, 2009. 5:14 AMwilwrk4tls says:
 Another option may be to make a base for the router that the router screws into.  I have a different radial arm saw but could probably do something similar- interesting project.

I have a project in the works using a router to make a pocket hole machine- another one I similarly wouldn't use terribly often and really don't need a dedicated machine for.
Dec 23, 2009. 8:03 AMwilwrk4tls says:
 Will do- I'm on the tail end of moving, so once I get more settled (AND get more done on the project : ) I will put that one up
Jan 7, 2010. 4:16 AMwilwrk4tls says:
Moved from Chattanooga to Hixson, so more of a new residence than changing cities.

I put up an Instructable on the pocket hole jig- I will include pictures of the real deal when I unearth it.  I can't paste a link for some reason, but it should come up with a search of pocket hole jig.


Dec 22, 2009. 1:57 PMkissiltur says:
I can't to step 10 for some reason - it links to the intro. That applies for the link from the intro page, and the "Next Step" link from step 9.

Weird.
Dec 23, 2009. 9:19 AMkissiltur says:
Works now - now I know why it's called a pin router!
Dec 22, 2009. 4:08 AMrimar2000 says:
I like that radial arm saw increasingly, Phil. Seems a very useful and versatile tool. I suppose it must be expensive, I have not seen "personally" any similar. 

I'm feeling
desire to make one "poor man's" of these at home, now that I retire from work this 30/12. Maybe for 2011...

Your instructables are increasingly good.
Dec 22, 2009. 1:57 PMgdufford says:
Hi rimar, something you might be interested in is the Lindsay Publications. They have lots of very helpful and easy to read booklets on making your own tools. They have a series that starts with a small aluminum foundry, then on to a handmade metal lathe (that uses the foundry), then a milling machine (that uses the lathe) and on and on.

Read a few of these booklets and you'll be able to make your own radial arm saw if you have the time, aptitude and interest. Not sure if they have Spanish versions, but the pictures are the most valuable part.

They are far from "slick", basically pretty crude little books, but the information inside is great. www.lindsaybks.com/prod/index.html

Good luck
Dec 22, 2009. 3:52 PMrimar2000 says:
Thanks, gdufford, I will see that. I can read English pretty good. Google and other on line translators helps me very well.
Dec 22, 2009. 9:06 AMrimar2000 says:
Here in Argentina the miter saws are named "sensitiva" (you can see http://listado.mercadolibre.com.ar/sensitiva [today 1 U$S = $arg 3.81 ===> 1 $arg=0.262 U$S] ) But nobody could explain me why they are called so.

Besides not having seen in my life a radial arm saw, I have not seen an ad of it.

I'm bad for business, if I start distribute those saws in Argentina , sure I go broke and lose the house. If I start making bras, women begin to come without breasts...
Dec 22, 2009. 4:32 PMgrunthos says:
The "sensitiva" name may be similar to the "sensitive" drill press, where the operator can feel the operation of the tool in the downward force.  See http://www.wisc-online.com/objects/MTL8502/MLT8502.htm
Dec 22, 2009. 5:42 PMrimar2000 says:
Thanks, grunthos, it seems that's how you say. But then, it is a fanciful name, because on that approach, all hand tools should be called sensitive.
Dec 23, 2009. 9:04 AMgrunthos says:
I agree, it is a strange name.  I have seen the name in English and American books for over 100 years for drill presses, but I have not seen it for any other tool.  It does make you wonder how certain names get stuck like that. 
Dec 22, 2009. 12:40 PMrimar2000 says:
Really, that is a very good price!

If you can get the CIA to hire me, you will have 50% of my salary ...

That yes, I promise that I will not manufacture bras


Dec 22, 2009. 1:51 PMgdufford says:
Hey Phil, nice router jig! I'm certainly going to use this sometime. I've used my router lots of different ways, but never on the radial. Very cool.

Hopefully my radial arm saw has the same type of tapped holes. I'm going to look at it tonight to check.

The only thing I'd do differently is the part in step 4. I'd try to mount the jig to the round protruding part of the motor housing. It looks about the same diameter as the router clamping bit and could be made the same way. It would probably be a bit sturdier than the eyebolt.

I assume your "drawings" are done in SketchUp? Now that I finally know how to use it I'm loving it. Not always the most intuitive, but very fast to use once you get the knack of it. I designed the jig for my Cardboard Ball Chair (www.instructables.com/id/Cardboard-Ball-Chair/) using it.

Keep up the good work!
Dec 22, 2009. 2:25 PMgdufford says:
You're right about the eyebolt being quick and easy. My approach would've added considerable time for sure. Usually a good sturdy jig is worth the time to create (even if you only use it 1 time), but there are always exceptions. My chair project started running so long I had to make some compromises where normally I'd setup a jig of some kind.

You know what made the difference for me with SketchUp? Watching the basic tutorial videos.

I do software for a living and rarely read manuals (RTFM?). SketchUp is actually easy to use, but not obvious. This is a subtle but very important distinction. I found that working with guidelines, grouping/making a component frequently and learning the alignment techniques made a world of difference. Path following is a little tricky at first, but VERY powerful. Spend a half-hour or so watching the tutorials and it'll be like night and day.
Dec 22, 2009. 12:53 PMLithium Rain says:
Looks awesome!
Dec 22, 2009. 2:02 PMLithium Rain says:
Of course. Keep them coming! :D

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Author:Phil B
I miss the days when magazines like Popular Mechanics had all sorts of DIY projects for making and repairing just about everything. I am enjoying posting things I have learned and done since I got my...
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