Sturdee's foot switch.

**Sturdee** · 23rd October 2004, 06:13 PM

When using certain machine tools it would be very handy to have a third hand. You could use your normal hands to operate the tool and hold the work as usual and a third one to quickly switch off the machine in an emergency. This would be very handy when using a drill press or a table mounted router.

So for a long time I have been looking to make something that could replace a third hand something like a footswitch that could turn of the machine in an emergency. I have been looking at using vacuum cleaner switches but these proved too difficult to safely built in a jig.

Then I looked at sewing machine foot controls. The new ones are not suitable as they don’t use 240 volt or they use compressed air. However the old ones are perfect. I obtained two old Singer foot controls from a sewing machine retailer (one of the small local independent ones who does their own servicing) and adapted the plug that normally fits into the sewing machine with a normal power point outlet.

I have been using one on my drill press for about a bit over a month and am very pleased with it. In use I line the drill bit to just above the timber and press the footswitch to operate the machine and release the footswitch to stop the machine. The footswitch works like a dead man switch (ie. Only while pressed in). This is the equivalent to using an NVR switch, as the motor can not start by itself.

Photo 1 shows the switch connected to the drill press.

Photo 2 shows the two units with the power point outlets connected. I used a chipboard block to mount the outlet, cheaper to use an old outlet than buy a plug and it hides the wiring.

Photo 3 shows the inside of the first unit. This one could be used without modification as the resistors/diodes? were working okay.

Photo 4 shows the inside of the second unit. This one would not switch of so I removed the resistors/diodes? and bypassed them using the blue jumper wire. Now it works okay.

To trace the wiring for connecting the plugs I used a cheap volt meter continuity tester.

There are many more uses than a drill press for a footswitch eg scroll saw and handtools that are mounted into jigs and the second one will become one of those tools that will be used more and more.

***WARNING *** Electrical work can be lethal and although this gadget is not illegal to wire up yourself as it is not directly connected to the main wiring if you are not absolutely sure of how to do it get an electrician to make it for you.

Peter.

**jow104** · 23rd October 2004, 07:19 PM

Looks another good idea from the master jig builder.

The sewing machine that my wife uses (Pfaff) the footswitch operates like an accelerator pedal, and her previous machines did the same. Hve you bypassed this operation?

I have in the past had footswitches operating my music keyboards that operate "on then off", The are quite cheap in the U.K. (Korg type or Yamaha but have different electronic setup inside the pedals)

Perhaps someone with electrical knowledge can give them the once over as well.

**Sturdee** · 23rd October 2004, 07:35 PM

Originally Posted by jow104

The sewing machine that my wife uses (Pfaff) the footswitch operates like an accelerator pedal, and her previous machines did the same. Hve you bypassed this operation?

The ones I got are ofcourse old but kept by the sewing machine shop owner as he is loath to throw things out. The variable speed control doesn't work anymore. On the first the rest of the switch worked fine and so no work was needed but on the second I had to bypass the variable stuff .

The good thing is that they were free and he has more if I need them.

Peter.

**ozwinner** · 23rd October 2004, 07:54 PM

Peter!!

Why do you want to switch feet?

Al :confused:

**Sturdee** · 23rd October 2004, 08:18 PM

Originally Posted by ozwinner

Peter!!

Why do you want to switch feet?

Al :confused:

In case you need to borrow mine and hang them amongst the others in your shop.

Peter.

**Caliban** · 23rd October 2004, 08:27 PM

Peter
boom, boom.LMAO
I tried to give you a greenie but wasn't allowed.

**E. maculata** · 23rd October 2004, 10:27 PM

Nice Adaptation Peter, had thought about the sewing machine controls as well, but was lucky enough to acquire a proper foot control from a fitter mate, and yep I too use mine on the drill press, and metal lathe just in case things get abit wobbly :eek: bleedin handy that way.

**simon c** · 24th October 2004, 08:23 AM

You can buy on-off foot switches from electrical outlets like Middy's for about $30 and then wire them into an extension or powerboard. I use a powerboard so I can also plug the vacuum/dust collector into it so it switches on at the same time.

**Abug** · 24th October 2004, 12:43 PM

A foot switch is the best thing I ever built for use with my dads but now my MK3 bench. I built one back in 1992 when I was 17. I used good quality switch and with x2 cable glands and 2 cables coming off it with a male 240volt plug on one and a female 240volt plug on the other Male plug went into the power lead while the female plugged into the workbench switch box.

The only thing with a sewing machine footswitch is to make sure the contacts can handle the load of the drill or whatever you use it for, and also the cable size. The cable on this mod looks like it may be 0.75mm cable where it should be at least 1.5mm cable. But definately easier to stop the saw instead of reaching for the stop button.

I was just a 2nd year Electrical apprentice then.

**jow104** · 24th October 2004, 06:49 PM

Welcome Abug, I hope your user name doesn't give us too much trouble

**Sturdee** · 24th October 2004, 06:49 PM

Good to hear that others find a foot switch as handy as I do. I wouldn't use a drill press without it anymore.

Abug thanks for your advice on checking that the switch can handle the load of the tool.

I use it for the drill press and will use it for handheld tools that are incorporated in a jig, eg biscuit jointer and the dremel tool. As these motors are not very big I'm sure that the switch can handle it , but probably not my Mk3 workcentre or Triton router.

Peter.

**himzol** · 26th October 2004, 10:55 AM

Just on foot switches,

All the lasers I work with have a foot switch actuator, all have a metal hood over the foot switch to stop you accidently stepping on said switch when walking around.
Peter you may want to make something like that up for your units, it may not be necessary but I've always been of the opinion that you can't be too carefull.

Himzo.

**SWR** · 26th October 2004, 03:16 PM

Hello Sturdee,

Might I say, nice work!

I discovered the old problem of needing a third hand myself and came to the same conclusion that a foot switch was the way to go.

Jaycar Electronics, which are in most states sell a foot switch rated at 250V 10A which is ample for most applications. I have mine switching a 2 outlet 240V outlet mounted to a sturdy piece of timber with a foot guard bent up out of flat aluminium to prevent accidental operation. Here is the code for it:

<TABLE cellSpacing=0 cellPadding=2 width="100%" border=0><TBODY><TR><TD class=type width="72%" bgColor=#f2f2f2>JAYCAR - STOCK-CODE: SP0760

I have converted my homemade table saw and my bandsaw both to foot switches and it gives me both hand free to do the safe thing...

Of course it goes without saying that if you don't know what your doing get a sparky to do it...cause mains will kill you soon as look at you...it can bite really hard, so don't risk it.

But when/if you do convert something to foot switches, you,ll wonder how you survived without them!

Cheers'n'beers to all.

Scott.

</TD></TR></TBODY></TABLE>

**simon c** · 26th October 2004, 06:17 PM

Scott,

They look just the ticket. Will be buying a couple this weekend.

**scooter** · 26th October 2004, 10:38 PM

How much are those Jaycar ones Scott?

Sean

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