Sunday, February 27, 2011

The bandsaw died.

Perhaps you were expecting an update about the bartered woman syndrome?
Hah!
The paint has to dry first. Actually it has to be applied first. So the pics will have to wait, and the story will continue later.

Meanwhile back at the ranch, the bandsaw stopped starting.
At first it was thought to be a problem with the switch.
The saw is twenty um years old and the switch was maybe getting tired?

So we took it apart and saw that it was literally choked with decades of fine dust and the lever arms could no longer travel far enough for the contacts to meet and pass electricity.

The air compressor took care of the dust problem, and the switch was reassembled.

But it was installed in  an inconvenient location so we decided to put it up where it was easier to find and switch off if needed.

Here is the tale of relocating the switch from the lower stand to the back of the casting that holds the upper wheel.

Phase one was to acquire an electrical box to hold the switch. And step two was to drill and tap a couple of holes in the cast iron frame to hold the surface mount box.  Look at the pretty picture and see the tap. Click on it for a bigger image.


I used a # 10 by 24 thread machine screw with 5/64 drill to tap the threads.
Here is the box installed.



You can see the box has plenty of holes and cracks to let dust in, so the next phase was a bit of sealing with a hot glue gun.

Here is the gun. A cheap one but it does the job.



After sealing around all the cracks and extra holes with nylon glue, the whole box was covered with silvery duct tape.

Next the wire from the motor was lead through the stand and shielded with a plastic fitting so it wouldn't chafe.
I rewired the switch and assembled the interior by attaching the ground wires first.




When I connect wires I try to arrange the stripping and sconnectors so that there is no naked wire available to make accidental contact.



After testing the switch, the final assembly proceeds, sealing the cracks with duct tape on top of the glue seals.



And there it is. A relocated switch that is safer because the machine operator does not have to seek at belt level for the thing is he or she wants to switch off quickly.

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