Thread: 10 inch blade in a 9 1/4 inch power saw ... The WIP

A while ago I started the thread "10 inch blade in a 9 1/4 inch power saw?" to brainstorm the safety, viability, safety, performance and ... safety of removing the retractable guard from the 235mm powersaw I keep permanently mounted in my Triton WC2000 tablesaw so as to have the clearance to install a suitable 254mm blade. My goal was essentially to maximise the cutting depth of my WC2000 if this was a safe and simple option. See thread:
http://www.woodworkforums.ubeaut.com...ad.php?t=45256
I would like to thank everyone who contributed to the thread allowing a frank and open discussion of all experiences, opinions and objections with this proposed mod. I think it a great testament to the people who through their contributions make this forum such a powerful source of communication.
I would like to offer the opinion I have developed after this process seems to have exhausted the emergence of any more issues to be discussed. PLEASE NOTE: THE FOLLOWING MOD IS SOMETHING I'VE TAKEN ON MYSELF AND IN NO WAY A RECOMMENDATION FOR OTHERS. This preamble might seem a bit OTT for some but I understand and respect that some contributors had and still maintain concerns about the advisablity or safety of this mod. I ask you to consider their opinions by reviewing the above thread and make your own decision as whether this mod is a good idea for you and your machine.
My personal opinion is that with my GMC Platinum 2300W 235mm circular saw with a maximum no load speed of 4500rpm permanently mounted in my Triton Workcentre 2000 it is safe to remove the retractable guard from the saw and install a 254mm 3mm kerf blade with a maximum speed rating 6000rpm.

Three bits of extra advice:
1) Don't get a thin kerf blade for this mod - they flex more and with the larger diameter blade increase the possibility of taking chunks out of the sides of the aluminium blade slot. If your saw is struggling either slow your feed rate, get a blade with less teeth, go back to a 235mm blade, or get a more powerful saw.
2) Make sure the blade travels freely in the fixed guard of your saw by manually spinning the blade backwards (with the power off of course).
3) Make sure you check the maximum / no load speed of your saw against the maximum speed rating of the blade to make sure you don't exceed the blades design specs.

The great news is that I made the mod, it was very easy and it works beautifully. I have increased my maximum cutting depth from around 62mm to slighty over 72mm - an increase of 14%. Everything from the chassis to the tabletop to the clear overhead guard fits perfectly and all my test cuts with 70x40mm jarrah have produced pristine results with ease. I am about 2000% happy with this mod!


Here are some pics:

1st pic) Carry Pine suggested Makita made a 10.5inch blade so I went looking. The closest I could find in stock was this 10.25"/262mm blade for a Hitachi cutoff saw. Unfortunately it only cleared the fixed guard on my saw by barely 1mm which I didn't feel was enough so I returned it to Bunnies (note: apparently IRWIN have discontinued this line).
2nd pic) A picture of my saw with the blade out exposing the circlip that holds the retractable guard on. I removed this (cheap circlip spreading pliers cost about $5), removed the retractable guard, a washer and the spring and then replaced the circlip. I have the removed parts stored together in a ziplock bag.
3rd pic) My saw with the retractable guard removed and the (40 tooth) 10"/254mm blade installed. Note the easy clearance from the base and the fixed guard - 8-10mm in most places. The smallest clearance is at the towards the bottom of this pic near the dusty hose mount - a quite reasonable 5mm or so.
4th pic) WC2000 assembled with new blade in saw and clear overhead guard attached. Note the abundant room for the blade.
5th pic) Close up of a measurement of the depth of cut at the low side of a saw tooth - 72+mm .