|I built my Wall Saw to make the accurate cutting of sheet
material very easy. It has also proved to be great for trimming and squaring Table
Tops after glue-up. The wall saw is one of my favourite tools. I made it after
seeing one at Bunning's. You can buy plans of the Web but after looking at them I thought
it would not be that hard. Below is the Reader Digest condensed version of how to build
Get some aluminium thick walled pipe for the rails and some alum. plate and square pipe for the Saw Holder/Traveller. The saw table (backing board) is just melamine sheet with an A frame support. The saw is my old Ryobi 7 1/4" which should get some new bearings and brushes real soon. A couple of things are also needed, the Saw needs a counter-balance which hangs down the back of the unit. I found an old sash window weight (the old cast iron ones) as the salvage yard. (I actually got two but found that one was just right.) The Saw is perfectly balanced and will sit at any position.
For the Saw Traveller, I just used some alum plate with square alum cleats
top and bottom. The Traveller is connected to the rails via four pieces of plastic
obtained from - (don't laugh, frown, etc) - two very, very thick old Breadboards. I forget
the name of the plastic but it is very strong when it is thick and this is the cheapest
way to get it. Anyway, these pieces have holes cut in them exactly the same size as the
Rails. As the plastic is slippery but not flexible, the saw moves up and down very well
and accurately. Just for safety, I have four U-Bolts around the rails as well. I put these
on as insurance but the saw has been in use for over two years now and I check it
regularly and the plastic has not worn at all.
Last couple of things, my saw is mounted on casters so I can move it around nice and easily however, when I do, I recheck the alignment. This is actually recommended for the commercial units as well. The other thing is that behind the saw table (i.e. in the A Frame) I store my Sheet goods. This saves lots of space, keeps them of the ground and upright which are all really good things.