Mike Kelly
02-21-2005, 12:25 PM
Ken, Keith, Aaron. If you deem this worthy, you can place in "Article and Reviews" if you want to.
Excalibur Guard Installation on a Delta Unisaw with Unifence and Delta Mobile Base.
Loosen the Unifence and slide it to the left to allow space for drilling bracket holes behind fence. See Figure 1.
The first items to construct are the Brace and Upper Brace on the far right side of the saw’s table. I used 2-inch angle iron from Home Depot for all of the attachments. These cuts can be made with a hacksaw or an abrasive cut-off saw if you have one. File the edges smooth to protect yourself on all cut offs.
Measure the inside dimension from the Unifence mount to the rear table mount and cut a piece for the Upper Brace. Look at Figure 2., and buy two right angle brackets also from HD. Stanley makes them. Look at the Figure 3. picture and note that the two holes drilled through the front attachment bar for the Unifence have to be countersunk. Use flat head screws for these two. I think they were 3/8” x about 1” hardware with lock washers under all nuts.
Measure the dimension across the bottom of the mobile base and cut a lower Brace the same size. Doesn’t really have to span the whole length. I drilled two mounting holes and bolted this to the mobile base.
Look at Figure 4., and mark a pencil line 1 inch closer to the rear of the saw than what the Excalibur instructions tell you. (I made mine to their specs, 8 inches, and it is too close to the front of the saw. It works OK, but it would be better 1-inch farther rearward.) Note the awl in the picture is pointing to the line. Use 7 inches from the rear edge of your table. (Step 2 of their instructions minus one more inch.)
Look at Figure 1., and Figure 5., and see that I had a clamp holding the arm in place while I marked the foot position. Make sure everything is vertically straight and plumb at this point. Drill two mounting holes for the Excalibur Lower Column Assembly to mount to. Bolt it to the side.
Construct the Excalibur Foot, Figure 6., from 2 pieces of angle iron, drill a mounting hole through both and bolt to the lower brace.
Next construct the Excalibur Foot Adjust bolt, Figure 7., out of allthread, 4 nuts, and four washers. Drill a mounting hole through the Excalibur leg and the lower Brace and Mobile Base. You may have to drill the holes through the leg first, mark the bracket where the hole comes out and then drill through the Brace and Mobile Base. Mount the allthread with the nuts and washers, put a level on the top and adjust until you have it where you want it, tighten the nuts and you have a more solid mount than their Mickey Mouse bracket affair, plus you don’t have to work around their brackets which I think would eliminate your lower table area.
I took mine apart after I built it and spray painted it flat black with Rustoleum and reinstalled. Looks like it belonged there all along.
Good luck.
I will add Figure 6 & 7 as a response.
Excalibur Guard Installation on a Delta Unisaw with Unifence and Delta Mobile Base.
Loosen the Unifence and slide it to the left to allow space for drilling bracket holes behind fence. See Figure 1.
The first items to construct are the Brace and Upper Brace on the far right side of the saw’s table. I used 2-inch angle iron from Home Depot for all of the attachments. These cuts can be made with a hacksaw or an abrasive cut-off saw if you have one. File the edges smooth to protect yourself on all cut offs.
Measure the inside dimension from the Unifence mount to the rear table mount and cut a piece for the Upper Brace. Look at Figure 2., and buy two right angle brackets also from HD. Stanley makes them. Look at the Figure 3. picture and note that the two holes drilled through the front attachment bar for the Unifence have to be countersunk. Use flat head screws for these two. I think they were 3/8” x about 1” hardware with lock washers under all nuts.
Measure the dimension across the bottom of the mobile base and cut a lower Brace the same size. Doesn’t really have to span the whole length. I drilled two mounting holes and bolted this to the mobile base.
Look at Figure 4., and mark a pencil line 1 inch closer to the rear of the saw than what the Excalibur instructions tell you. (I made mine to their specs, 8 inches, and it is too close to the front of the saw. It works OK, but it would be better 1-inch farther rearward.) Note the awl in the picture is pointing to the line. Use 7 inches from the rear edge of your table. (Step 2 of their instructions minus one more inch.)
Look at Figure 1., and Figure 5., and see that I had a clamp holding the arm in place while I marked the foot position. Make sure everything is vertically straight and plumb at this point. Drill two mounting holes for the Excalibur Lower Column Assembly to mount to. Bolt it to the side.
Construct the Excalibur Foot, Figure 6., from 2 pieces of angle iron, drill a mounting hole through both and bolt to the lower brace.
Next construct the Excalibur Foot Adjust bolt, Figure 7., out of allthread, 4 nuts, and four washers. Drill a mounting hole through the Excalibur leg and the lower Brace and Mobile Base. You may have to drill the holes through the leg first, mark the bracket where the hole comes out and then drill through the Brace and Mobile Base. Mount the allthread with the nuts and washers, put a level on the top and adjust until you have it where you want it, tighten the nuts and you have a more solid mount than their Mickey Mouse bracket affair, plus you don’t have to work around their brackets which I think would eliminate your lower table area.
I took mine apart after I built it and spray painted it flat black with Rustoleum and reinstalled. Looks like it belonged there all along.
Good luck.
I will add Figure 6 & 7 as a response.