This is my table saw. It isn't much but it works for me. Looks fine doesn't it. OK, perhaps it is a little dirty but aside from that everything is functional and safe. But it is just a facade. In reality my little saw is putting on a brave face. For you see, years ago, it lost one of its rubber leg bumpers. Oh, sure, it has made its way through life without it. But there are times when I can tell it feels a little self conscience about its missing foot. If I go to a new work site I have to make sure that it has the support it needs to be level. So for all of the help it has given me, I decided to give some help back to it. A new rubber foot was in order.
Step 1: Clean and Apply
For the new foot I took advantage of our local maker's space Instructable night and used Sugru for the first time. If you aren't familiar with it, Sugru is (from their website) "self-setting rubber that can be formed by hand. It moulds like play-dough, bonds to almost anything and turns into a strong, flexible silicone rubber overnight". Sounds like the perfect stuff to make a replacement rubber foot out of. So I wiped off the dust and by hand formed a new foot onto the metal of the leg. I used a couple of measurements to make sure that the end result was the same height for each leg. That's it. Just form it by hand. The stuff sticks well, the yellow color didn't level a discoloration on my fingers, and it held its shape well over a small span.
Step 2: A Little Support
To make sure that the edge of the leg didn't cut through the Sugru after a few moves, one of my fellow makers suggested giving it a little support. So we rough sanded a scrap bit of 2"x we had laying around and zipped tie it in place until it cured. The Sugru was easy to form over the wood and metal. And in fact, the next day it seemed to have locked the two pieces together. I will go in and replace the zip ties with wood screws through the two openings on the leg but even without that, the wood seems secured to the leg.
Step 3: A Little Extra Security
As we were finishing up, one of the young makers suggested that we secure the other feet on and wondered if the Sugru would work to help stick the remaining, original, rubber feet on. I didn't know so we tried it.
Laying a thin line of Sugru in the cavity of each foot was as easy as rolling a 'snake' in clay. Once in we pushed the feet onto the metal leg. The next day? Using a small effort, I was unable to pull the foot off of the leg. If I had done this when I first got the saw I probably won't of had to make a new foot for my saw.