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  1. #1
    Join Date
    Apr 2004
    Location
    United States
    Posts
    317

    Talking Overhead blade guard system

    Ever had something that started one way and then went another? I did. I bought an overhead guard for my cabinet saw and it caused as many problems as it cured. Well I kept the basket and mounting clamps and trashed the rest, here's where it gets interesting. As this went along, I found I had designed something that not only worked well for me, but I think others would be interested in and could be marketable. As that happened, I figured out other ways that it could be used to the point I don't think there's a overhead guard on the market today that can offer all the options this one has and someone with a well equipped machine shop can build one from scratch, so I'm thinking maybe have some company make it or sell plans if nothing else.

    I can't show it yet because I have some legal stuff to do yet, but I can give you a taste of what's possible. Hopefully I'll be able to show it off soon.
    Based on measurements I got, it should work on almost all contractor, hybrid or cabinet saws from about 8" to around 14"-16" blades. It's scalable, meaning certain measurements can be changed, depending on a particular situation. It can be mounted from the left or right side of the saw, left or right tilt saws. Shouldn't make a difference whether you have a splitter or riving knife on the saw, if the basket will cover it then you should be ok. Long as a mount can be fabricated, should work with almost any basket that will cover the blade and splitter. It's irrelevant how you want to mount it: floor, off the mobile base, surface mount, off the back or rail of the saw or even off the ceiling: it can be mounted in any of those ways as long as there's a spot to mount it to. Plenty of clearance over the table and about 5"-6" under the basket when it's raised to the max while cutting. If you need it clear of the table, that only takes a few seconds and if you need it taken off; that can only take a few seconds also. If the basket has provisions for dust collection, that can be handled too and if configured certain ways you don't even have to disconnect the dust collection when clearing it from over the table or removing it in most mounting situations.

    I happen to like both baskets I used for development. One works well for thin cuts (cutting 1/8" wide strips while the other guard works better in other situations. Because of the way I designed this thing, I made 1 extra part and I can switch them out in about 30 seconds or less.

    Then more thoughts came to mind. If you're like me and do raised panel doors on a shaper or router table, that big chunk of spinning steel makes you want to pucker every time you spin it up. I came up with a way that the same pieces could be used to help protect you from that too.

    I had to either do or hire out some metal bending and cutting, some welding, drill and tap some holes to make the system. The main things I didn't make or have made was the splitter which I already had ( I purchased the 2 baskets, 1 came with the original overhead guard I purchased and the other is a design a gentleman makes), as there are too many good sources out there for those items. Even the one basket I used has plans available. Even building all 5 mounting methods (excluding the baskets and splitter used in development), I still came in under 20% of the highest priced overhead guard I found and it was about 30% less than the one I originally bought that didn't work so well.

    That's my tale for the day, more to come.

    Paul

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  3. #2
    Join Date
    Jul 2006
    Location
    Canberra
    Posts
    296

    Default

    ...I still came in under 20% of the highest priced overhead guard I found and it was about 30% less than the one I originally bought that didn't work so well
    I'm interested in overhead guards, making or buying at the upcoming Sydney shindig, but this statement doesn't make sense to me - if it's 20% less than the highest priced guard found, how the can it be 30% less than the one you originally bought? Apart from quantum (tm), it would mean that guards have come down a lot since you bought yours, even the highest priced ones: something I find hard to believe (that they have come down in price that is )...

    Rob

  4. #3
    Join Date
    Apr 2007
    Location
    Kalamunda, WA
    Age
    52
    Posts
    1,989

    Default

    Seen these? Recommended by Bill Pentz

  5. #4
    Join Date
    Apr 2004
    Location
    United States
    Posts
    317

    Default Guard

    McArthur - High end Biesemeyer lists for up to $1000 here, depending on the model you get. The systems I looked at run anywhere from $174 for a PSI up to $1000 for one of the Biesemeyers (retail prices) on the web, most run in a $350-$500 range on average. I have around $200 in materials for one complete system including mounts for every mount I noted (except a splitter which I already had). By making the duplicate parts and remaking some, I know I purchased enough materials to basically make 2 systems, had I some complete plans in the first place. Even building duplicate parts, it's still better cost wise (other than the PSI) and that one does not have near the features this does. Unfortunately the PSI doesn't offer anywhere near what this one can do, even before I started designing the prototype, I'd removed PSI from consideration in my pre-prototype purchasing days.

    Ever see a ceiling mounted UniGuard, or a floor mounted one? Well I have one. I've already used the Uniguard basket on the rail mount, ceiling mount, floor mount and I haven't even tried it on every conceivable setup yet. How about a guard system that one minute has a Uniguard basket on it, and with a simple change is now sporting a Shark Guard or one suitable for usage on a shaper/router? Mine does and I have pictures to prove every thing I've mentioned.

    Burnsy - I know Lee's work very well. In fact I bought one of his baskets in developing my prototype. The cost of his basket is included in the $200 number I mentioned earlier and I paid retail for all my materials. Whether you come in less or more than that depends on what tools and equipment you have vs what you have to hire out and what you pay for your materials, along with what configuration you build (the simplest vs the most complex) or even multiple systems. Lee's stuff is good but try doing a dado or rabbit cut with his guard on and see what happens. I've talked with Lee regarding being listed as a source for the basket if someone wanted to order one of his and he is agreeable to that. I also briefly talked with him about producing the basket I put together configuring for the router or shaper situations. Nothings set yet, but it's a possibilty. This thing not only will work in selected situations with shapers and router tables, but also if you have a tablesaw extension that mounts a router. This can lend itself to far more situations and machinery than any other guard I know of or I had originally even thought of.

    Ever wish you had a light to spot directly on what you're cutting? I've already set up 2 different variations of that.

    I've had several people helping evaluate the design, ranging from newby's to long time woodworkers. They have equipment ranging from contractor saws up to a 14" Northfield. So far, we haven't found a situation it's not been able to work in. You do need a spot to mount the guard. If one isn't available there's usually at least one other option available. I still a little spit-and-polish to put on it, but so far there hasn't been anything from a functional standpoint it's not been able to handle. I don't claim to be a metalworker, so if I can make it, any person with reasonable skills should be able to do it even better.

    I'm not making the baskets or splitters as there are many good units out there. I used the Shark Whale from Lee and the Bob Ross' Push-pull splitter in developing this prototype. I didn't include Bob's splitter in my costing as I already had that and didn't buy a comparable item for development.

    Hope that answers your questions. I've asked my evaluators to try and nail it with every conceivable issue they could come up with. There have been some enhancements due to it and right now it's getting down to the nits.

    Paul

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