Messages

1

General Scroll Saw Talk / Re: Dewalt 788

« on: November 29, 2021, 11:25:29 am »

Does your saw perhaps have a lifter accessory that holds the arm up when changing blades or setting up for an internal cut?  Mine uses a spring similar to what you describe to hold the arm up.  This is external to the "innards" of the saw, spring at back above the motor.

2

General Scroll Saw Talk / Re: DeWalt 788 blade clamp distance issue

« on: December 29, 2020, 11:10:53 pm »

OK folks, back for an update...  Based on web research a couple months ago, I suspected that my saw was from a batch with an out-of-spec tensioning wedge.  I never could find details on the issue, but was able to order a new one for about $11 with shipping, so worth a gamble.  After finishing up Christmas gift projects, and watching (studying!) the great DeWalt scrollsaw repair videos by the Gwinnett club, I felt ready to tear into my saw.  Followed the video advice to clean and re-lube all the bearings (all in OK condition thankfully), then tackled my blade distance problem. 

In one of the attached pics, you can see the wedge at the top rear of the saw.  Cranking the tension lever pulls the wedge forward, forcing the upper arm of the saw upward, increasing tension.  Since the replacement wedge I received was exactly the same size as my old one, I first tried adjusting the rod connecting the lever to the wedge "longer", going up to 8 turns (at about 1mm per turn) to where the edge was back about as far as it will fit under the upper plate, and only gained about 0.3" on blade clamp screw distance; still about 4.7" center-to-center.

I figured what the heck, and used a large flat file to cut down the top surface of the wedge.  It's aluminum, so easy to file (a milling machine would have been even easier!).  After multiple tries, I ended up taking the top surface down about 0.1" (2.5mm) - see original and cut down replacement pic.  I got my blade clamp C-C distance down to about 4.25".  Still a bit over the nominal which I believe is 4.125", but MUCH better than the "barely close enough" I had before.  Haven't tried cutting yet, but will tomorrow after finishing re-assembly.

Cheers and happy new year!
Rick

3

Introduce Yourself. / Re: New member to the Forums

« on: December 06, 2020, 12:19:30 pm »

Welcome Buzz!

Looks like you're off to a good start 

4

General Scroll Saw Talk / Re: DeWalt 788 blade clamp distance issue

« on: November 18, 2020, 08:25:19 am »

Hi Dave,

I ran across the Gwinitt service videos last weekend researching this topic.  Watched the first "intro" one then realized the others totaled HOURS as you describe.  Very thorough!  I also ran across info on Rick Hutcheson's site (scrollsaws.com) with tune-up info on the 788.  That is where there is info on the tensioning wedge and issues within a certain manufacturing "range" with that part being too large in some dimension causing issues that sound like mine - but frustrating never describes the issue in detail.  I'm tempted to go ahead and order a new wedge, as I can get one for ~$6 plus shipping.

I may put more investigation on hold (while I wait for that part), since upcoming Christmas + grandkids = toy and puzzle projects.  Then tackle a more in-depth tear-down once that "production pressure" is past.

Thanks
Rick

5

General Scroll Saw Talk / Re: DeWalt 788 blade clamp distance issue

« on: November 16, 2020, 09:08:10 pm »

Hey Dave, thanks for the input!  And I'm not offended (my ideas have been called way worse than crazy!)

At lunch today I took the table off my saw and snapped a few pics of the blade holders and arms.  I have a Jim Dandy arm lift, and thought for a minute THAT Was limiting how far down the upper arm can go, but it doesn't limit the motion.

So need some wisdom from the experts here...  From the pics is it obvious what the issue is?  Like do I have two upper arms instead of the proper upper and lower?  Something else look not-assembled-right?  I have not had my saw apart at all since new (not TONS of use over 8 years).

Thanks
Rick

6

General Scroll Saw Talk / DeWalt 788 blade clamp distance issue

« on: November 15, 2020, 08:44:40 pm »

Hi Folks,

Have had a DW788 for about 8 years (not as active in use as many on here!), and always struggled a bit when installing blades: distance between blade clamps just barely gets close enough when untensioned.  Bought a different brand set of blades (Pegas, was using Flying Dutchman for some time) and now even more challenging.  While reading online last night on various DeWalt issues and fixes, read that the standard blade clamp center-to-center distance is 4-1/8".  Measured mine today and untensioned it's almost 5 inches!! (we'll call it 4.95").  Of course with 5" blades that barely gets the ends to the centers of the clamp screws if you're careful - which is why I found it frustrating that when installing a blade I had to get down on my knees with a flashlight to check bottom end in that clamp!  I also measured some blades, and the Flying Dutchman I had been using are a bit longer at 5.1", the new Pegas just a shade over 5"

In my research I saw mention of an issue with the tensioning wedge being out of spec for a certain period.  My saw is a Type 2 per motor tag, SN 200604-CJ14807 for those who may know how to decode this.  I couldn't find specifics of what dimension(s) are out of spec and what nominal is.  Could this be the issue causing my "daddy longlegs) blade clamp distance?  Other thoughts?

Thanks!
Rick in Oregon