hope its ok to revive this ancient thread.
I almost have my jig, as shown about the middle of this long thread, done.
but I did something stupid. In building this jig to be able to safely rebuild clutches, I had an oops.... I know why and how it happened, and what I could have done different, but it is what it is. got complacent more than anything, and I shouldn't have used the rip fence along with the cross cut (miter) guide.... but I thought "only need 2, and great way to make sure the dimensions were right" since I had just ripped that 1" rough sawn oak to 2-5/8" wide, 2 saw-cuts before... for what ever reason. I had my 2 blocks cut, as called out in the thread, but for some unexplained reason I decided to cut a 3rd one " just in case" I split one while assembling, or something... and #3 was the one that bit me.
if I'd have stopped after the 1st 2 were done, I'd have been OK... should have used an aux fence that stopped short of the blade, clamped to the saw's rip fence... or used the chop saw for the cross cut... even if I just needed 1 block of wood that size. I did this last Sunday, and have since "taken the week off" from being in the garage. could have done with 2 days, but I want my forehead to be "less obvious" when I go back to the saw..... in case the neighbor comes out to see what I'm building while I'm over there.
I 1st ran a table saw, ~40 years ago (my Dad's) and though its not something that I do every day, it's something I have done plenty of, over the last 40 years// enough to know better I guess....but I still screwed up this time.
In cutting the 2-5/8" X2-5/8" X 1" thick blocks, one of them decided to kick back on me, deflect off my right thumb which was holding a push stick, (and cut it, too) right into my forehead..... Its almost healed now, but was bad enough to freak out the wife/ and get her to try and drag me to the ER to be stitched up....
told her I wasn't going anywhere-- and didn't. It drew blood, which I had stopped up, before she saw me.....
I have owned a few table saws myself over the years. and used them plenty.
especially during, and for a few years just after, high school.
It seems that in these days of Craigslist and such it's easy to buy such a piece of equipment for the duration of a project then re-sell it when done.
I sold my last table saw a couple years ago for space considerations, and because I have a neighbor who was constantly on me-- "hey, I'm only 2 doors down, and have anything for woodworking that you'll ever need"... I had given him my radial arm about 10 years ago, besides....which he still has. so I was over there cutting out all these blocks of wood.. I cleaned it up, came home, and didn't tell him what I did.... he'd laugh it off at this point anyways... but being he is a retired nurse and his wife is still a nurse, I might get a bit of a "talking to", that would be the worst of it from him.... but I vacuumed all the sawdust and wiped up my blood stains and went home.... no biggie (but it "could have been") My Dad had a He11 of a wood shop too/ that equip is still there, my brothers use it all the time, but they aren't 30 miles away from the old house, either, like I am.
I have 1 more piece to cut... gotta rip a 4X4 down to the 2-5/8 X 2-5/8" and cut it to (I forget which, it isn't in front of me) either 6" or 8" long then I can glue and screw, and I can try my jig out on this PITA 1200 that is clogging my garage and get it outta here. ( it ain't the machine that is a PITA, but the machine's owner)