Re: Chop Saw Stand

@Bro Rosy

Initially I planned it to be the same height but in the end I opted to raise it higher so I don't stoop down too much when aligning cut lines.

I will build some risers for the welding table in case I need it to help support longer pieces to chop.

Re: Chop Saw Stand

Metal order finally came so can now continue with the WIP again.

1 1/4" x 1 1/4" square tubes for the support arms

Top plates and caster wheel plates

the metal store can't avoid plate warping during cutting ( Oxy LPG ) specially for 1/4" & 1/8" thickness ... I need to flatten these out a bit but after the welding table's warped 1/2" plate top ordeal .... this will be like a walk in the park LOL

Pwede din palang mini welding table ito pag hindi naka mount yun chop saw ... 1/4" top 16" x 22" LOL

Re: Chop Saw Stand

I'll fab the caster plates now. I find it a lot better if the casters are bolted rather than welded directly to the frame. Maintenance wise it would be easier to replace.

I choose the tap and drill size suitable for the install. 8.0 x 1.25mm tap and a 6.7mm drill bit.

marked the caster bolt locations and bored the holes on the first plate

I need to drill 3 more plates with exactly the same hole positions. Now there are a lot of options here since the plates can still be brought to the drill press. I can overlay one into another using the first plate as the guide. However I decided to test the transfer punches and mark each hole position separately.

Hole transfer punches are not like center punches. You just have to tap these lightly in order to make the impression on where the hole center would be. Whacking these would be a surefire way to destroy the precision points. Layout fluid if available can also make markings easier to see.

the one on the top is a center punch while the one on the bottom is a hole transfer punch.

Re: Chop Saw Stand

Center punched the plates for hole locations then proceeded to drill ....

Now for the tapping .... the most important thing is to have straight holes and straight taps. Any deviation on the 90 degrees entry angle can cause tap breakage not to mention issues when tightening the bolt

here a tap guide would be a useful tool to have ...

Re: Chop Saw Stand

Norseman taps have a very aggressive cut and chip ejection design. Usually when tapping one needs to cut in the clockwise direction then after sometime back off a bit counterclockwise to relieve pressure. Not with these taps ... very seldom to do a counterclockwise turn as it can cut continuously.

With the Gator tap guide I can tap while sitting down. There is no need to stand up and view the tap alignment if it's ok or not. The jig makes sure that the tap will enter 90 degrees relative to the plate.

Re: Chop Saw Stand

Will weld and bolt these later ...

I chopped some 1 1/4" x 1 1/4" x 1.5mm square tubes for the extensions

this is the proper way to chop square tubes but would probably talk more about it later

I planned for 6.5' of adjustable extension. The 1 1/2" x 1 1/2" x 1.5mm square tubes are a bit loose as support for the extensions ... will look at it again later ... if not I will fab custom sized receiver tubes.

Re: Chop Saw Stand

The 1/4" plate middle bow is no match for the welding table's clamping stability .... it had no choice but to straighten out.

Casters installation

for Moji ....

Re: Chop Saw Stand

I need to cycle my power tools' batteries .... no air tools for this portion ... only cordless.

I also tapped the frame. Tapping is a skill thus the more practice the better.

Re: Chop Saw Stand

Just enough welds ...

if there is a bolt or nut involved 90% of the time I will be using an impact driver ... be it air or battery powered

Casters installed ... these will only be taken off again during the painting job.

Re: Chop Saw Stand

These tools had been very very helpful in this build that I just need to post and give credit.

Angle grinders on duty for this WIP ... 2 Bosch , 1 Makita, 1 Metabo and a Dewalt.

Now I need to think about how to go about the extension install. I will have to modify an existing square tube or build a custom sized receiver tube.

Re: Chop Saw Stand

These tools had been very very helpful in this build that I just need to post and give credit.

Angle grinders on duty for this WIP ... 2 Bosch , 1 Makita, 1 Metabo and a Dewalt.

Now I need to think about how to go about the extension install. I will have to modify an existing square tube or build a custom sized receiver tube.

Yes, truly these angle grinders are a must specially during metal fab projects. hahaha, try finishing a metal project without them, its very difficult to finish one. Angle grinders are very versatile tools, they can cut metals, grind edges and unwanted burrs, de-rust and polish a metal surface, shape welds etc, but of course with the use of proper attachments.

GO GO GO bro, doing good with the chop saw stand, nearing completion already !!!:2thumbsup:

Re: Chop Saw Stand

Yes, truly these angle grinders are a must specially during metal fab projects. hahaha, try finishing a metal project without them, its very difficult to finish one. Angle grinders are very versatile tools, they can cut metals, grind edges and unwanted burrs, de-rust and polish a metal surface, shape welds etc, but of course with the use of proper attachments.

GO GO GO bro, doing good with the chop saw stand, nearing completion already !!!:2thumbsup:

What Bro Rosy says is very true. An angle grinder is an essential must have tool for metal working.

If I could only have one grinder I will choose a 4.5" variable speed model. If not I will go for the Bosch 4" 8-100CE variable speed which is available locally.

Re: Chop Saw Stand

I was busy with other matters today so nothing really eventful .... none the less i shot some pics of the work done.

I did cut the extensions ( 6.5' ) , rounded the edges of the swivel base and wire brushed the metals to be used later.

1/4" more and this will be the final overall height of the chop saw ... high enough that I won't have to stoop down ... the table is 32" high

Re: Chop Saw Stand

The plate to be used for the swivel is bowed ... will probably need to fire up the oxy ace torch to flatten it ...

I also took a closer look at the receiver tubes ... this is 1 1/4" x 1 1/4" x 1.5mm square tube inside a 1 1/2" x 1 1/2" x 1.5mm tube ... too much gaps ...
I would need at least 16 or 14 gauge plates to fab custom receiver tubes or I could line up the insides with flat bars to lessen the gaps to an acceptable tolerance.

Re: Chop Saw Stand

I also took a closer look at the receiver tubes ... this is 1 1/4" x 1 1/4" x 1.5mm square tube inside a 1 1/2" x 1 1/2" x 1.5mm tube ... too much gaps ...
I would need at least 16 or 14 gauge plates to fab custom receiver tubes or I could line up the insides with flat bars to lessen the gaps to an acceptable tolerance.

Bro JayL,

So there is an amount of space or gap between the receiver and the extendable tubing, say about 1/4" or 3/16" of an inch, if I were to line up a flat bar of about 1/8" or 3/16" thick to compensate for the gap, I'd rather place it on the outside two surfaces of the extendable tubing rather than the insides of the receiver. One on the underside and another on the left or right side.
You can easily clamp the flat bars and correct any mistakes, do some adjustments, then can easily apply Mig welds on the edges probably by stitch welding or spot welds to prevent some possible warping, then grind or shape and polish/buff excess welds. 😉

Bro if you will apply it inside the receiver tubing, ma we welding mo lang ang mga dulo ng flatbar at edge ng tubing. 🙁