Messages

1

Tutorials, Techniques and Tips / Cost saving tip when replacing DW788 bearing sleeves

« on: September 21, 2021, 03:23:32 pm »

If you own Dewalt DW788 scrollsaw, sooner or later you will need to replace a number of bearing sleeves. I am referring to short, long, and drive link bearing sleeves. I find them expensive when ordering from online stores, not to mention the shipping costs to Manila.

Bearing sleeves help your scrollsaw to run smoother and quieter. It can also help to reduce a lot of knocking effects and vibrations on your scrollsaw.

Short and Long bearing sleeves measure 6mm outside diameter, 4mm inside diameter.
Drive link bearing sleeves measure 8mm outside diameter, 4mm inside diameter.

With these specifications, I bought stainless capillary tubes measuring 250mm long for both sleeves. I have them cut at a machine shop to exact length of the sleeves, bringing the original sleeves as samples to follow. Ensure that the cuts will be clean cuts, no metal burrs, fine cuts with little bevel on edges.

With these, I was able to produce a lot of ready to use sleeves, ready to replace any worn out sleeves whenever my DW788s call me to do so. Cheers from Manila!

—-oops—-
Please apply good quality grease (eg Valvoline synthetic high temp grease or equivalent) when re-inserting new sleeves.

2

Tutorials, Techniques and Tips / Re: Rewinding DW788 motor

« on: September 05, 2021, 06:20:56 pm »

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Updated: Sept 8, 2021
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I watched lots of youtube videos, i will check the links and post it here soon. But prior to rewinding DW788 motor, here are the recommended steps to know.

1. How to disassemble/assemble DW788. This is a very important step. Gain some experience and confidence that you can properly deep dive into parts of DW788. Thankfully videos abound in youtube.
https://www.youtube.com/watch?v=_6KJbyZQwko
https://www.youtube.com/watch?v=x42jZgEAUwM&t=506s
https://www.youtube.com/watch?v=Y9xdJ8L-teg


2. Basic knowledge of how motor works. Particularly AC motors. Get familiar with parts of the motor and terminologies.
https://www.youtube.com/watch?v=CWulQ1ZSE3c



3. You need tools, multimeter tester, proper size wrench, screw driver bits (philips, flat, star, hex), pliers, etc.
https://www.youtube.com/watch?v=HqxH_TGlntw

Don’t be confused with the language, just look at their actions, tools, etc.

4. Be sure it’s a motor problem. It’s  no joke to disassemble the motor, only to find out it’s  still working.
https://www.youtube.com/watch?v=HNJZhPHdHhw
https://www.youtube.com/watch?v=lmjFzukDhqI

5. If it is motor, watch videos how to remove armature and how to test armature for failures in its winding coils. Do not rewind unless you know how to test armature. You will use the same skills after rewinding anyway.
https://www.youtube.com/watch?v=GDKZBBmvJiI
https://www.youtube.com/watch?v=l9MIpaIgEiw

6. Watch videos who have rewinded motors, particularly armature rewinding. Need not be DW788 motor but get an idea, see how to terminate the coils, etc.
https://www.youtube.com/watch?v=l9MIpaIgEiw&t=53s
https://www.youtube.com/watch?v=Gy4rtgvd9Y8

7. Prepare your materials like Wire gauge, I used AWG 27. Magnet wire. Insulating varnish, cotton strings. See videos how to apply insulating varnish after rewinding.
https://www.youtube.com/watch?v=v2YaSLWKOQE
https://www.youtube.com/watch?v=n5XcGlvlW5c
https://www.youtube.com/watch?v=9L1wJVItwN4

Don’t mind the native language pls. Just see how to do apply varnish.

8. Test..test…test.

3

Tutorials, Techniques and Tips / Rewinding DW788 motor

« on: September 05, 2021, 12:18:56 pm »

Just to share my experience rewinding my DW788 motor, saving me at least $300 + shipping per motor replacement. I have 3 units of DW788, but 2 of them developed  motor related issues after 2 years of using it. I cannot afford to buy new units nor new motors. I tried a number of rewinding services shops, but they would not rewind my motors. I got no option but to rewind it myself. Thankfully, after many weeks of studying motor rewinding basics via youtube, I figured out how to rewind dw788 motor. Now have all units working like new, not to worry again about motor related issues. Hello from Manila!

4

Tutorials, Techniques and Tips / DW788 Type 2 motor heating up

« on: September 05, 2021, 08:28:25 am »

I have been monitoring my DW788 Dewalt scroll saw motor. It heats up easily. Sometimes too hot when working for about 1 hour. The motor doesn’t have any fan or ventilation by design. I added a mobile usb powered fan to help it cool down. At the end of the motor shaft, there is a small hole where I installed the fan.

If you want to see actual photos look for “DW788 Dewalt Scrollsaw” FB group.