Why Does Cosmos Build a Big Table Saw?

Because he can!
Aug. 26, 2017
4 min read

Because he can!

Given what it costs to buy a table saw there is no good reason to build your own. And yet watching this video by Cosmas Bauer makes me want to make one, even though I already have two. Why? Because there is something very satisfying about building your gear—be it a workbench, router jig, or any machine of your own design.

Bauer lives in Germany and has been producing these videos for years. You’ll see him use a couple of his earlier creations to build the saw in this video. He begins by showing what the saw can do; the build happens later in the video.

Here are some of the highlights:

(0:40) This machine is built around the guts of an old direct-drive Sheppach jobsite table saw, so Bauer does not have to fabricate an arbor or drive system. Sheppach is a brand of tools sold mostly in Europe.

(1:09) I like the looks of the homemade fence—slides very nicely. Note the metal top. More on it later.

(2:21) I like how the router fence keys into one of the miter slots.

(2:53) The build begins here…

(3:11) Screwing into captured dowels is a clever way to increase the holding power in plywood. I’d have probably used biscuits and/or pocket screws to assemble these joints.

(3:34) Bauer rips pieces for the big saw on a small saw he built some years back.

(5:12) The mechanism pivots on pins that land on a metal trunnion piece fabricated earlier in the video.

(7:33) If you’re wondering why the plywood top has such a big hole in it, it’s because a steel plate will cover the plywood.

(8:42) Installing the steel tops. Note how he gaps the plates to create the miter slot.

(9:12) Bauer uses a track saw and metal cutting blade to trim the steel top flush to the wood below. It’s a strain for such a small saw, so he switches to the home-made metal cutting saw he built in an earlier video.

—David Frane is a freelance editor and a good buddy of ours. Formerly, he was editor of Tools of the Trade magazine and website. He lives in Northern California.

You can support me via: Patreon: https://www.patreon.com/CosmasBauer Amazon: https://www.amazon.de/registry/wishlist/3RPBBTHSA42Z9/ref=cm_sw_em_r_mt_ws__T7ebzbT5WYXQT Instagram: https://www.instagram.com/cosmasbauer/ Over the course of more than a year I built this table saw. Table saws like these, without some sort of whimpy wannabe sliding table are rare in Europe. And I wanted a decent one. Making Hand Wheels: https://www.youtube.com/watch?v=hse8MiVmm6o Chop saw to circular saw conversion: https://www.youtube.com/watch?v=o9093a_TV_o Cutting the table saw insert hole: https://www.youtube.com/watch?v=7sC1QGMxlbg Cutting Sheet metal acurately: https://www.youtube.com/watch?v=MwUdZvshuCA For the body of the saw I made a simple box out of birch plywood. The corners were rabbet joined and pulled together with screws. After that was done I made the cutout for the crank shaft using a template and the jigsaw. The motor unit from the Scheppach saw (TKU) was hung inside the box on two home made steel hinges. Then i made a follower nut and mounted it to the motor unit using a piece of steel shaft. I drilled the hole for the tilting spindle which I used an M 20 threaded rod for and mounted it to the box using a pillow block. After that I made the sub-top out of birch plywood which I mounted the steel table tops on top of. After the base for the saw was done and the home made fence system attached it was basically ready for use! I took the motor unit of my Dad's old job site saw and built the rest of the saw around it. Thanks, Dad!

About the Author

David Frane

David Frane is a freelance editor and a good buddy of ours. Formerly, he was the editor of Tools of the Trade magazine and website. He lives in Northern California.

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