Hey folks, I'm having a bit of a problem with my DeWalt DWE7491RS table saw. I've set it up in my workbench, but the aluminum top isn't level; it dips in the middle, which makes it really difficult to properly square the blade with the table. I'm considering a couple of options:
1. Finding a local metal shop to resurface the saw top to get it as flat as possible.
2. Building a new top with a torsion box, or simply clamping a 3/4 inch MDF piece and waxing it for a smoother surface.
I'd really appreciate any insights or suggestions you might have since I'm on a budget and eager to tackle some home improvement projects like a bathroom vanity and cabinets. Thanks a lot!
3 Answers
Your aluminum top might be too thin to machine properly, which complicates things. Creating a new top could become a lot of work, especially if you have to factor in how the miter slots and fence will work with it. I'd suggest either trying to hammer it into shape or selling it off to get something better, like a used cast iron model that can be found for a decent price.
I've got a different take on this. If you're looking for something that's 'farmer flat' rather than perfectly flat, I had a similar issue with a cheap table saw I bought for $30. I took it apart and, using a 4lb hammer and some 2x4s, I carefully hammered it until it was pretty level. It was a bit of a process, but it worked well enough for heavy use until the motor eventually gave out. Just keep in mind it might take a few tries, but it can be done!
Honestly, you might want to consider just upgrading to a new saw with a cast iron top. I found one at a big box store for under $800 with a solid reputation. It'll definitely make your build projects a lot easier!
Yeah, new parts can add up, and getting a secondhand saw might be a better investment in the long run. It's worth checking out options on platforms like eBay for a used one!