Replies

1. 
   Steinmetz | Dec 22, 2004 12:03pm | #1

    desert man, drill a tiny hole through the center of brush covers  THEN ,while fitting the brush and spring unit, insert a stiff wire with which to poke the spring cap ahead of the cover It,s like a third hand.  Steinmetz

    

    

    

2. 
   JohnWW | Dec 22, 2004 06:25pm | #2

   Yeah, it's an incredibly annoying design flaw.  Steinmetz's solution is elegant, but I had success with using a straightened out paper clip with a small right angle on its end to hold the spring in place while I slipped the cap back on.

   John W.

3. 
   KeithNewton | Dec 23, 2004 04:45am | #3

   Hold it in with one finger while you slip the edge of the cap in from the side replacing the finger pressure with the cap pressure.
   Said another way . Use the cap to push the holding finger out of the way while keeping cap pressure on the top of the brush with the other hand.

4. 
   desertmaster | Dec 23, 2004 10:41pm | #4

   Thanks a bunch for the replies. I'll try rootburls method, then consider the drilled hole and wire suggestions.   Thanks.

5. 
   Steinmetz | Dec 24, 2004 03:27am | #5

   Des,  I once had a 8" heavy duty ballbearing skill saw ,which after a few years overheated a rear ballbearing and laid down on me.

    The housing (Like most today) was plastic and the bearing was fused to the plastic

   The repair guy disasembled it and discovered the melted in bearing . He gave up and gave it back in pieces in a box

   I bought a new bearing and drilled a small hole from the rear of the housing and punched the old bearing out and pressed in the new and that was 12 years ago and I still use that saw not havind had to buy another since.

    

   I recently built an entire table saw from wood. utilizing an old early 6" skill saw.

     I converted the saw unit to accomodate a 6-1/2' blade (Sold for Cordless circular saws)

   It is very accurate and as the blade is thin, it's great for anything under 3'"in thickness (Or, 6" if you flip the stock over).

   It stands 27" when in its stand and only 9" high when removed from the table.

   After months of daily use, it failed to start  'til I discovered the brushes were a 'mite' too short

   As a quick fix was needed, I placed one each lock washer inside the brush cover's caps  and now the brushes are 1/16" longer and I'm back in business.

   Have to 'Spring for new brushes if I run out of washers.  L O L  Steinmetz

   
   

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   Edited 12/23/2004 7:33 pm ET by steinmetz

1. 
   PlaneWood | Dec 24, 2004 05:13pm | #6

   Steinmetz -

   Years ago when doing commercial cabinets I needed a table saw for on site use.  Not wanting to port my Rockwell 10" around, I opted to make a plywood table saw using my Porter Cable circular saw.

   I made it with a 4'x3' plywood top and with plywood folding legs.  The PC was bolted underneath.  Had a 3/4" dadoed groove for the miter slider.  Used c-clamps and a straight board for the guide.  Taped the handle switch down and had an on/off switch on one of the legs.

   I was amazed at how handy it was and good of a job it did.  All my on-site needs was just with 3/4" thick material, about half and half ripping and cross cutting.  Don't remember exactly what blade I used but it was a good thin kerf carbide blade.

   PlaneWood by Mike_in_Katy (maker of fine sawdust!)PlaneWood

1. 
   Steinmetz | Dec 25, 2004 04:40pm | #7

   Mike, you're a man after my heart /clone of myself. The quick set up for my Skilsaw was exactly like yours although I secured the switch with twisted wire instead of tape.

   Setup was over a pair of horses or an open top barrel

   I don't rememember how many times I set it up

    in my driveway to cut up tree limbs and entire trees 

    to bundle up for trash removal

   Actually my neighbors would cart it off for firewood.

   The one I mentioned I recently made has a rip fence

   that rides on rails attached to the tables 'skirts'

   Tightens up with thumb turns (Wing nuts)

   This one has a seperate on/off switch

   Plus a  key switch (Ignition type)for extra safety.

   To make the unit as small as possible,

    I cut off the grip handle and any thing else

   taking up space under the table top.

   Just made a tenoning fixture for use on the TS

    Made it from orange crate plywood .

   (Still has the Grower's brand name on it.)

   Stein.

6. 
   vertis | Dec 26, 2004 07:57am | #8

   I have a Freud router it is a strong,and well laid out tool but this machine has a torsion type spring for presure but the center pin that holds the spring is poor in design and will eventually break off,so now you must replace the brush holder unit by having to take the motor apart to replace the unit.Now I had a fear of reassembling the tool and hope that it would not go out of alignment(fortunately it went back together O.K.)But I am like yourself,why should a .50cent part be such a pain in the #*^ to install.LOL.