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Detailed step by step instructions on how to upgrade your miter saw fence system, using the aluminum extrusions 30xx series.
This video also features building the mini clamp, as well as the stop block, which work perfectly with the upgraded miter saw fence.
The miter saw fence system upgrade also fixes the problem of the factory fence up/down movement, which was preventing the default factory setup from the tiny material clamping capabilities.
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TOOLS / COMPONENTS
1. Dewalt Miter Saw DWS779 ( DWS780 adds XPS LED shadow casting system for the precision cuts, but I can't see it on Amazon, the only difference between DWS779 and DWS780 is XPS LED system):
https://amzn.to/2UhzyYz
2. Stainless Steel Ring Eye Bolts M6
https://amzn.to/2TDxdqy
3. Aluminum Flat Bar 1/2"
https://amzn.to/3qdOWkI
4. Aluminum Flat Bar: 3/8"
https://amzn.to/3zC4N0r
5. Stainless Steel Flat Head Bolts M6 Set:
https://amzn.to/3vzra3p
6. Aluminum Extrusions 3060
https://amzn.to/3cSaLAJ
7. T-Track
https://amzn.to/3q6pq0r
8. T-slot Nuts ( select 3030 series M6 )
https://amzn.to/3gzurLP
9. Stainless Steel M6 Bolt Knurled Knobs:
https://amzn.to/2TKOE8t
10. Copper Column Spacers M5 (for the "gate" in Mini Clamp (select M5 inner x 18 mm long )
https://amzn.to/2SIgOkv
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With the above mentioned improvements to your miter saw, you will be able to execute the precision cuts on the wood / soft metals or acrylic / plastics, including cuts of the tiny components.
It is recommended to combine the miter saw fence system upgrade + mini clamp + stop block, with the zero clearance platform, so that the tiny pieces won't fall into the factory wide gap insert. I demonstrated the zero clearance in this video too.
The stop block looks as simple as it can get, but it is truly universal, and would work both with and without the zero clearance platform, and on other machines fences using the same 30xx aluminum extrusions fence system (see my other videos on upgrading the table saw and miter gauge using alu extrusions here:
). The universal factor of the stop block is achieved by the thoughtful design of the slot length + position on the stop block wall.
The mini clamp is built from the waterproof / oil proof materials: hardened stainless steel clamping foot, SS hardware, SS anchor eyelet bolt, aluminum holder, alu spacers, alu solid block, alu threaded peg, alu slider.
The idea for the mini clamp design comes from my ultimate bar glue up clamps, which you can see here:
This design, which I call a "gate" (because it resembles the gate structure with pillars + top), allows the main M8 SS long bolt angled movement, which results in the capability to clamp round stock or other irregular shaped material.
I know the video turned out quite lengthy, (please excuse me for that) but I didn't want to omit the important steps should one want to reproduce my build process.
The video in fact contains 3 (if not 4) projects, but I prefer to keep them as one video, as they are closely related and interdependent.
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