Grizzly G1023Z owner's manual: Section 5: set up

SECTION 5: SET UP

Unpacking

The Model G1023Z Series Table Saws are shipped from the manufacturer in three carefully packed boxes. If you discover the machine is damaged after you have signed for delivery, immediately call our Customer Service for advice.

The Model G1023Z Series is a heavy machine, weighing up to 460 lbs. Personal injury could occur if the machine is moved without additional assistance. Seek the help friends when moving or lifting the machine.

Piece Inventory

When you are completely satisfied with the condition of your shipment of boxes, you should inventory their parts.

CAUTION Sharp edges on metal parts may cause personal injury. Examine the edges of all metal parts before handling.

Box 1:

Figure 9A. Shop Fox® fence components.

Box 2:

Figure 9B. Motor cover assembly.

Box 3:

Figure 9C. G1023Z Series component layout.

After all the parts have been removed from Box 3, you should have:

1. Extension Wings (2)
2. Miter Gauge
3. 5/8"-18 Blade Guard Mounting Shaft
4. Arbor Wrench
5. 5/8" Combo Wrench
6. Blade Guard Assembly
7. Handwheel Knob Bolt
8. Handwheel Handle
9. Dado Blade Table Insert
10. Standard Blade Table Insert
11. Dust Port
12. Cleanout Door
13. Hardware Bag
14. Table Saw Unit (Not Shown)

The hardware bag should contain the following:

(1) 3mm Allen Wrench (1) 4mm Allen Wrench (1) Combo Wrench 5/8" (1) 5/8"-18 Blade Guard Mounting Shaft (1) 5/8"-18 Hex Nut (4) #8 x 3/8" Self Tapping Screw (4) #8 Flat Washer (2) 1/4"-20 x 3/8" Phillip Head Screw (2) 1/4" Lock Washer

Hardware Recognition Chart

Use this chart to match up hardware pieces during the assembly process!

Clean Up

The unpainted surfaces are coated with a waxy oil to protect them from corrosion during shipment. Remove this waxy oil with a solvent cleaner or citrus-based degreaser such as Grizzly's G7895 Degreaser. To clean thoroughly, some parts may need to be removed. The machine will operate best when the waxy oil is removed from all moving and sliding parts. Chlorine-based cleaners and solvents will damage the painted surfaces of the machine. Follow the manufacturer's instructions when using any type of cleaning product.

Gasoline or petroleum products used to clean the machinery could explode causing serious personal injury. DO NOT use gasoline or petroleum products to clean the machinery.

WARNING Smoking near solvents could ignite an explosion or fire causing serious injury. DO NOT smoke while using solvents.

WARNING Lack of ventilation while using solvents could cause serious personal health risks, fire, or environmental hazards. Always work in a well ventilated areas to prevent the accumulation of dangerous fumes. Supply the work area with a constant supply of fresh air using a fan.

Site Considerations

Floor Load The Model G1023Z Series Table Saws are a heavy load with a medium footprint. Most commercial or home shop floors should be sufficient to carry the weight of the machine. Reinforce the floor if you question its ability to support the weight.

Working Clearance Working clearances can be thought of as the distances between machines and obstacles that allow safe operation of every machine without limitation. Consider existing and anticipated machine needs, size of material to be processed through each machine, and space for auxiliary stands or work tables. Also, consider the relative position of each machine to one another for efficient material handling. Be sure to allow yourself sufficient room to safely run your machines in any foreseeable operation and keep dust collection hoses off the floor and out of the way.

Lighting Lighting should be bright enough to eliminate shadows and prevent eye strain. Electrical circuits should be dedicated or large enough to handle combined motor amp loads. Be sure to follow local electrical codes for proper installation of new lighting or circuits.

Unsupervised children and visitors entering a shop could receive serious personal injury. Ensure child and visitors safety by keeping all entrances to the shop locked at all times. DO NOT allow unsupervised children or visitors in the shop at any time.

Beginning Assembly

Keep clothing rolled up and out of the way of machinery and keep hair pulled back.

WARNING Disconnect power to the machine when performing any maintenance or assembly. Failure to do this may result in serious personal injury.

WARNING Wear safety glasses during the entire assembly process. Failure to comply may result in serious personal injury.

CAUTION Some metal parts may have sharp edges on them after they are formed. Please examine the edges of all metal parts before handling them. Failure to do so could result in injury.

TOOLS REQUIRED: You will need a high quality square, a long straightedge, 10mm, 12mm, 14mm open end wrenches and a 3mm Allen® wrench.

Extension Wings

WARNING The table and the wings represent a very heavy load. DO NOT over-exert yourself while lifting or moving the table and the wings – get assistance.

To attach the extension wings to the saw:

1. Attach the left wing to the table using the (3) 3/8"-16 x 1-1/4" Hex Bolts and 3/8" Flat Washers provided. Adjust the wing reasonably flush with the table and do not tighten the bolts completely at this time.
2. Attach the right wing to the table using the (3) 3/8"-16 x 1-1/4" Hex Bolts and 3/8" Flat Washers provided. Adjust the wing reasonably flush with the table and do not tighten the bolts completely at this time.
3. Align the top of the wings flush with the table top directly above the front bolts and flush with the front edge of the table. Tighten the front bolts.
4. Raise or lower the rear of the extension wings until the middle of the wings are flush with the table top. Tighten the middle bolts.
5. Raise or lower the rear of the wings until the wings and table are flush. Tighten the rear bolts.
6. Re-check the flushness of the wings against the table above each bolt. Re-adjust if necessary.

7. Check the alignment of the table and both wings with a straightedge. The straightedge should run flat across both wings and the table top. If the straightedge contacts both wings and the table evenly, you are finished with this section. If the straightedge does not contact them evenly, continue to Step 9.

8. If the extension wings tilt up or down at the outside edges, remove the wings and shim them with masking tape as shown in Figure 10.

A) If a wing tilts down, stick layers of masking tape along the bottom edge of the table and retighten.

B) If a wing tilts up, stick layers of masking tape along the top edge of the wing and retighten. Allow the tape to extend above table surface and trim the extended tape with a sharp knife after final assembly.

9. Re-check the alignment of the table and both wings with a straightedge and re-adjust if necessary.

Masking Tape Figure 10. Using tape to shim for wing alignment.

Fence & Rails

Your Model G1023Z Series comes with a Shop Fox® Brand Fence & Rails. Refer to the manual included in the fence box for assembly instructions.

Switch

The switch comes prewired to the motor and can be easily mounted to the rail.

To mount the switch:

1. Line the switch bracket holes up with the holes on the underside of the rail.

2. Secure the switch and bracket to the underside of the rail using the (2) 1/4"-20 x 3/8"Phillip Head Screws and 1/4" Lock Washers.

3. Disconnect the machine from the power source!

4. Connect the plug on the cord between the switch and motor.

Dust Hood

The Model G1023Z Series comes with a 4" dust hood and a cleanout door.

To mount the dust hood and cleanout door:

1. Mount the cleanout door into the square hole on the lower left side of the saw base.
2. Using (4) #8 x 3/8" Self Tapping Screws and #8 Flat Washer, screw the dust hood to the cleanout door.
3. Be sure to orient the dust hood so the 4" flange is on the lower half of the dust hood when installed as shown in Figure 11.

Cleanout Door Self Tapping Screw Dust Hood Figure 11. Installing dust hood.

Motor Cover

The Model G1023Z Series motor cover is designed to increase the efficiency of dust collection. The motor cover is packaged amd shipped in a separate box. It is held shut by a 1/4"-20 x 1/2" knob bolt as shown in Figure 12a.

Motor Cover Knob Bolt Figure 12a. Installed motor cover.

Motor Brace

A red motor brace has been installed for shipping purposes. Remove this brace before continuing with assembly. The bolts that secure the brace should be screwed back in at the locations from which they came.

Figure 12b. Motor brace.

Guard Bracket

NOTICE The blade guard mounting bracket (Figure 13) is supplied with the Shop Fox® Fence.

To install the blade guard assembly:

1. Thread the 5/8"-18 blade guard mounting shaft into the mounting location on the back of the table saw base as shown in Figure 13.
2. Secure the blade guard mounting shaft with the included 5/16"-18 hex bolt.
3. Slide the loosely assembled bracket onto the blade guard mounting shaft and temporarily hand tighten the nuts as shown in Figure 14.

Figure 13. Attaching the 5/8"-18 blade guard mounting shaft.

Figure 14. Blade guard mounting bracket

Handwheel

One handwheel has been removed for shipping. To install, place the handwheel over the threads and screw the lock knob into the center. Next insert the handle into the handwheel and tighten it as shown in Figure 15. Install the other handle onto the other handwheel.

Figure 15. Tightening handle onto handwheel.

Table Insert

The table insert provides support for the material being cut. It must be installed flush with the cast iron table surface.

To install the table insert:

1. Disconnect the machine from the power source!
2. Using the front handwheel, move the blade to its lowest position.
3. Set the table insert into the recessed area on the table surface.
4. Ensure that all four table insert setscrews (Figure 16) are firmly in contact with the table casting.
5. Using an allen wrench, raise or lower each of the four setscrews until the insert is flush with the table top.
6. Using the side handwheel, position the blade 90° to the table surface.
7. Wearing leather gloves, rotate the blade while raising and lowering it through its full range of motion. Make sure it never contacts any part of the table insert.
8. Repeat Step 6 with the blade in the 45° posi- tion.

Figure 16. Setscrews on each corner of insert.

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Saw Blade

To install a saw blade:

1. Disconnect the machine from the power source!
2. The arbor nut has left-hand threads. Loosen the arbor nut clockwise and remove the outside flange from the arbor. Remove and discard the 3/4" diameter spacer on the arbor shaft.

WARNING Use caution and remain alert when working with the saw blade. Failure to follow this warning could result in serious personal injury or death.

3. Install the saw blade onto the arbor. Ensure that the blade teeth point toward you as you stand at the front of the saw.
4. Slide on the flange and thread the arbor nut back on.
5. Use the arbor wrench provided with the saw to tighten the arbor nut. Wedge a block of wood in the teeth of the blade to keep it from turning when tightening the nut as shown in Figure 17.

Figure 17. Changing saw blade.

G1023Z Series Heavy-Duty 10" Table Saw

Blade Guard/Splitter

To install a blade guard/splitters:

1. Disconnect the machine from the power source!
2. Slip the blade guard/splitters over the mounting bolts as shown in Figure 18. The washers should be between the bolt head and the slots. Tighten the bolts to secure the blade guard/splitters.

Figure 18. Blade guard and splitters in place.

3. Set a machinist's square against the face of the blade splitters. Slightly rotate the rear bracket to adjust the face of the blade splitters perpendicular to the table top as shown in Figure 19.

Figure 19. Blade splitters square to table.

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4. Next, set a straightedge against the face of the saw blade and the blade splitter as shown in Figure 20. If the blade splitter is properly aligned, please skip ahead to Page 26; otherwise, continue with the next step.

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Figure 20. Guard in line with blade.

5. If the blade splitter is to the right of the blade as shown in Figure 21, simply add washers between the splitter and the front mounting bracket, and adjust the rear splitter support as shown in Figure 22.

Figure 21. Improper splitter/blade alignment.

Figure 22. Proper splitter/blade alignment.

6. Recheck the splitter alignment to the blade and to the table top. Adjust as necessary and tighten all the bolts before use. If the blade guard is properly aligned, please skip ahead to Step 13; otherwise, continue with the next step.

7. If the splitter is positioned to the left of the blade, alignment cannot be achieved by washer placement. Adjustment of the front support bracket is required. See Figure 21 for adjustment details. Loosen the 2 adjustment screws and move left or right.

8. If this adjustment does not allow enough movement of the splitter, remove the table and wings, and set them to one side. Be sure to note the position of the table shims. Replace them to their original position before re-attaching the table.

The arbor bracket and motor pulley now need to be adjusted:

9. Loosen the adjustment bolt shown in Figure 23, and slowly slide the arbor bracket towards the end of the shaft. Only move the arbor bracket a distance equal to the amount of misalignment between the blade and the splitter, or a little more. You can always adjust the splitter back to the left with washers.

10. Tighten the adjustment bolt securely.

Figure 23. Arbor bracket adjustment locations.

11. Moving the arbor bracket moves the V-belts and pulleys out of alignment, so adjustment of the motor pulley is required. Simply loosen the setscrew in the middle groove of the pulley, and slowly slide the pulley toward the end of the motor shaft. Once the V-belts are back in alignment, tighten the setscrew securely.

12. Recheck the guard alignment to the blade and to the table top. Adjust as necessary and tighten down all the bolts before use. If the blade guard is properly aligned, re-attach the table, making sure there is adequate blade clearance through all blade adjustments.

13. Adjust the blade to 45°. Raise and lower it through the full range. Re-adjust the blade to 90°, then raise and lower it through the full range. There should be no contact between the blade, the base, the table insert, or any other part of the saw. If there is contact, repeat Steps 8-12.

Miter Gauge

The miter gauge for the Model G1023Z Series has two setscrews in the miter bar which can be set to remove any loose movement between the miter bar and the T-slot.

To adjust the miter gauge:

1. Loosen or tighten the two miter bar setscrews (Figure 23) until the miter gauge slides freely in the slot, but has no loose movement.
2. Loosen the lock knob on the miter gauge and place a square against the face of the miter body and the miter bar.
3. Adjust the miter body until there is no space between the square and the miter bar.
4. Tighten the lock knob.
5. With the stop link (Figure 23) in the up position, loosen the jam nut and adjust the stop screw until it is seated against the stop link.
6. Loosen the setscrew on the left front side of the miter bar, adjust the pointer to 90° and retighten the setscrew.
7. To adjust to 45°, follow Steps 1-6 while using an adjustable square.
8. After rotating the miter body from 45° to 90° and back a few times, double check your adjustments at both angles to ensure that you have accurately set your miter gauge.

Figure 23. Miter gauge adjustment points.

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Start Up

Loose hair and clothing could get caught in machinery causing serious personal injury. Keep loose clothing rolled up and long hair tied up and away from machinery.

Projectiles thrown from the machine could cause serious eye injury. Wear safety glasses during assembly.

Before starting the machine:

1. Read this manual and make sure you take all safety precautions before operating this machine.
2. Make sure the blade guard and splitter have been correctly installed and are adjusted properly as shown on Pages 23-25.
3. Make sure that any tools or foreign objects have been removed from the machine.
4. Review Section 3: Circuit Requirements beginning on Page 8 and make sure all wiring is correct.
5. Keep your finger on the STOP button during the entire test run of the machine.

Starting the machine:

Turn the machine on and make sure your hand is on the STOP button in case you need to shut the machine off immediately. The machine should run smoothly with little or no vibration.

Recommended Adjustments

For your convenience, the adjustments listed below have been performed at the factory and no further setup is required to operate your machine.

However, because of the many variables involved with shipping, we recommend that you at least check the following adjustments to ensure the best possible results from your new machine.

All of these adjustments are covered in step-by-step detail in Section 8: Service Adjustments.

Recommended adjustment checklist:

• 45° & 90° Stops (Page 39)
• Blade Parallelism (Page 40)
• Blade Alignment (Page 42)

SECTION 6: OPERATIONS

Wear safety glasses. a dust mask, and hearing protection while the machine is running. Failure to do this could result in serious personal injury.

Blade Selection

Choosing the correct blade for the job is essential for the safe and efficient use of your table saw.

Rip Blade: Used for cutting with the grain. 10" rip blades have between 20-40 teeth (Figure 25), flat-top ground tooth profile (Figure 30) and large gullets to allow for large chip removal.

Figure 25. Ripping blade.

Cross-cut Blade: Used for cutting across the grain. 10" cross-cut blades have between 60-80 teeth (Figure 26), alternate top bevel or steep alternate top bevel tooth profiles (Figure 30), small hook angle and a shallow gullet.

Figure 26. Crosscutting blade.

Combination Blade: Used for cutting with and across the grain. A compromise between a rip blade and a cross-cut blade, a 10" combination blade will typically have between 40-50 teeth (Figure 27), an alternate top bevel and flat or alternate top bevel (Figure 30) and raker tooth profile. The teeth are arranged in groups of five. The gullets are small and shallow within the groups of five teeth, similar to a cross-cut blade; then large and deep between the groups, like a ripping blade.

Figure 27. Combination blade.

Plywood Blade: Used for cutting plywood or veneers. 10" plywood blades have 40-80 teeth (Figure 28), a steep alternate top bevel tooth profile (Figure 30) and very shallow gullet.

Figure 28. Plywood blade.

Thin-kerf: Designed for saws with smaller motors and for reducing material waste, thin-kerf blades are thinner than standard blades. Performance and accuracy can be maintained by the use of blade stabilizers.

WARNING Some blade guards/splitters are thicker than thin-kerf blades. DO NOT use the thin-kerf blade if this is the case or serious personal injury could result.

Dado Blades: There are two types of dado blades: stacked and wobble.

• Stacked Dado Blade—These dedicated dado cutting blades consist of a set of up to 8 individual blades. Multiple cutters are "stacked" between two outside blades. The width of the dado is determined by the combination of cutters that are "stacked" together. The dado is cut in a single pass leaving a smooth and square channel in the face of the workpiece as shown on Page 32. Stacked dado blades are the most expensive option but are worth considering if your projects require a lot of visible dado cuts. A typical stacked dado blade is shown in Figure 29.

Figure 29. Optional dado blade.

• Wobble Dado Blade—Also a dedicated dado blade, a wobble blade usually consists of a single blade that is tilted on the arbor shaft while it is spinning. The channel is cut in the face of the workpiece as the blade passes through its pre-adjusted width of travel. Wobble blades are an inexpensive option when visibly pleasing channels are not a concern.

Moulding Heads: A moulding head is a cutter-head that attaches to the arbor and holds individual moulding knives. They should only be used by professional woodworkers with training beyond the scope of this manual.

This section on blade selection is by no means comprehensive. Always follow the saw blade manufacturer's recommendations to ensure safe and efficient operation of your table saw.

Flat Top Blade

Triple Chip Blade

Alternate Top Bevel And

Alternate Top Bevel

Figure 30. Various saw tooth cutting profiles.

Crosscutting

A crosscut is a cut against the grain direction of the workpiece. Crosscutting man-made wood products like plywood is performed by cutting parallel to the shortest side.

Keep the blade guard in the down position at all times. Failure to do this could result in serious personal injury or death.

To make a 90° crosscut using the miter gauge:

1. Adjust the miter gauge to the 90° position.
2. Adjust the fence completely away from the cutting operation.
3. Position the miter gauge in one of the two miter slots.
4. Adjust the blade height so the highest saw tooth protrudes approximately 1/4" above the workpiece.
5. Hold the workpiece against the miter gauge and line up the cut with the blade.
6. Turn on the saw and allow it to come to full speed.
7. Hold the workpiece firmly against the face of the miter gauge and ease it into the blade as shown in Figure 31.

WARNING Turn off the saw and allow the blade to come to a complete stop before removing the cut-off piece. Failure to follow this warning could result in serious personal injury

Figure 31. Cross-cut operation.

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Ripping

A rip cut is a cut with the grain direction of the workpiece. Ripping man-made wood products like plywood is performed by cutting parallel to the longest side.

! Keep the blade guard in the down position at all times. Failure to do this could result in serious personal injury or death.

To make a rip cut:

1. Set the fence to the desired width of cut on the fence rail scale.
2. Adjust the blade height so the highest saw tooth protrudes approximately 1/4" above the workpiece.
3. Joint one long edge of the workpiece on a jointer.
4. Set up any safety devices such as feather-boards or other anti-kickback devices.
5. With the saw disconnected from the power source, rotate the blade to make sure it does not come into contact with any of the safety devices.
6. Plug the saw into the power source, and turn on the saw and allow it to come to full speed.
7. The jointed edge of the workpiece must be slide against the fence during the cutting operation.

! WARNING Stand to the left of the blade line-of-cut when ripping a board. Serious personal injury could occur if kickback results.

8. Using a push stick, feed the workpiece through the saw blade as shown in Figure 32, until the workpiece is completely past the saw blade. When a small width is to be ripped and a push stick cannot be safely put between the blade and rip fence, rip a larger piece to obtain the desired piece.

Figure 32. Ripping operation.

! Turn off the saw and allow the blade to come to a complete stop before removing the cut-off piece. Failure to follow this warning could result in serious personal injury

Dado Cutting

Commonly used in furniture joinery, a dado is a straight channel cut in the face of the workpiece. Dadoes can be cut using either a dado blade (Figure 57) or a standard saw blade.

!WARNING

Dado operations present very real hazards requiring proper procedures to avoid serious injury. The chance of kickback is always greater when dado blades are used so extra care must be taken. Any movement of the stock away from the fence will cause kickback. Be certain that stock is flat and straight. Failure to follow these warnings could result in serious personal injury.

To use a stacked or wobble dado blade:

1. Disconnect the machine from the power source!
2. Remove the table insert, splitter guard, and regular saw blade.
3. Attach and adjust the dado blade system as recommended in the dado blade manufacturer's instructions.
4. Install the dado table insert.
5. Raise the dado blade up to the desired depth of cut (depth of dado channel desired).

!WARNING

Never perform a through cut operation with a dado blade. A dado blade was designed to make non-through cuts only. Failure to follow this warning could result in serious personal injury.

6. If dadoing along the long length of your work-piece, adjust the distance between the fence and the inside edge of the blade to suit your needs as shown in Figure 33.

Figure 33. Single-blade dado cut.

!WARNING

Never allow hands or arms to be above or behind the saw blade. Should kickback occur, the hands and arms could be pulled into the saw blade causing serious personal injury.

!WARNING

Always use push sticks, featherboards, push paddles and other safety accessories whenever possible to increase safety and control during operations which require the blade guard and splitter to be removed from the saw. Failure to follow this warning could result in serious personal injury.

7. Reconnect the saw to the power source.
8. With one finger ready to push the OFF button, turn the saw on. The blade should run smooth with no vibrations or wobbling.
9. When the blade has reached full speed, perform a test cut with a scrap piece of wood.

10. If the cut is satisfactory, repeat with your finish stock.

ALWAYS replace the blade guard after dadoing is complete. Failure to follow this warning could result in serious personal injury.

Using a standard saw blade:

1. Clearly mark the width of the dado cut on your workpiece. Include marks on the edge of your workpiece so you can clearly identify your intended cut while the material is laying flat on the saw table.

2. Raise the blade up to the desired depth of cut (depth of dado channel desired).

3. If dadoing along the long length of your workpiece, adjust the fence so the blade is aligned with the inside of your dado channel as shown in Figure 34.

Figure 34. Single-blade dado cut.

WARNING Never allow hands or arms to be above or behind the saw blade. Should kickback occur, the hands and arms could be pulled into the saw blade causing serious personal injury.

WARNING Always use push sticks, featherboards, push paddles and other safety accessories whenever possible to increase safety and control during operations which require the blade guard and splitter to be removed from the saw. Failure to follow this warning could result in serious personal injury.

4. Turn on the saw and allow the blade to reach full speed.

5. Perform a test cut on a scrap piece of wood. Determine if the depth of cut is correct.

6. If the cut is satisfactory, repeat with your finish stock.

Always turn the saw off and wait until the blade has come to a complete stop before adjusting the fence. Failure to follow this warning could result in serious personal injury.

7. Re-adjust the fence so the blade is aligned with the other edge of the intended dado channel. Be sure to keep the cuts within your marks; otherwise, the dado will be too big.

8. Continue making cuts toward the center of the dado with your subsequent cuts until the dado is complete.

Always replace the blade guard after dadoing is complete. Failure to follow this warning could result in serious personal injury.

Rabbet Cutting

Commonly used in furniture joinery, a rabbet is a straight groove cut in the edge of the workpiece. Rabbets can be cut using either a dado blade (Figure 29) or a standard saw blade.

WARNING Rabbet operations present very real hazards requiring proper procedures to avoid serious injury. The chance of kickback is always greater when dado blades are used so extra care must be taken. Any movement of the stock away from the fence will cause kickback. Be certain that stock is flat and straight. Failure to follow these warnings could result in serious personal injury.

To attach a sacrificial fence:

Rabbet cutting with a dado blade requires the use of a sacrificial fence attachment as shown in Figure 35.

Sacrificial Fence Wood Screws Dado Insert Rip Fence

Figure 35. Sacrificial fence.

1. Disconnect the machine from the power source!
2. Cut a piece of wood that is as long and tall as the metal fence and 3/4" thick. This will be the sacrificial fence. Make sure the wood is a uniform thickness and free of knots and defects.
3. Attach the sacrificial fence to the metal fence with screws or clamps.
4. Remove the blade guard/splitter assembly, the table insert, and the regular saw blade from the arbor.
5. Install and adjust the dado blade system as recommended in the dado blade instructions.
6. Adjust the saw blade to maximum height needed for the rabbeting operation.
7. Raise the blade an additional 1/4".
8. Slide the metal fence with the attached sacrificial fence along side the blade.
9. Using a felt pen, draw the blade profile onto the sacrificial fence.
10. Remove the sacrificial fence from the metal fence.
11. Using a bandsaw or jig saw, cut the marked blade profile from the sacrificial fence.
12. Re-attach the sacrificial fence to the metal fence with screws or clamps.
13. Slide the fence assembly over the saw blade. The blade should NOT touch the sacrificial fence.

Cutting rabbets with the dado blade:

1. Adjust the saw blade to the maximum height needed for the rabbeting operation.

WARNING Never perform a through cut operation with a dado blade. A dado blade was designed to make non-through cuts only. Failure to follow this warning could result in serious personal injury.

2. If rabbeting along the long length of your workpiece, adjust the distance between the fence and the workpiece to suit your needs as shown in Figure 36.

Figure 36. Rabbet cutting.

Never allow hands or arms to be above or behind the saw blade. Should kickback occur, the hands and arms can be pulled into the saw blade. Serious personal injury could result.

Always use push sticks, featherboards, push paddles and other safety accessories whenever possible to increase safety and control during operations which require the blade guard and splitter to be removed from the saw. Failure to follow this warning could result in serious personal injury.

3. Reconnect the saw to the power source and turn the saw on.

4. When the blade has reached full speed, perform a test cut with a scrap piece of wood.

5. If the cut is satisfactory, repeat with your finish stock.

WARNING Always replace the blade guard after rabbet cutting is complete. Failure to follow this warning could result in serious personal injury.

Cutting rabbets with the standard blade:

Cutting rabbets with a standard saw blade DOES NOT require the use of a sacrificial fence.

1. Clearly mark the width of the rabbet cut on your workpiece. Include marks on the edge of your workpiece so you can clearly identify your intended cut while the material is laying flat on the saw table.

2. Raise the blade up to the desired depth of cut (depth of rabbet channel desired).

3. If the rabbet runs the length of the material, adjust the fence so the blade is aligned with the inside of your rabbet channel as shown in Figure 37.

Figure 37. Rabbet cutting.

Never allow hands or arms to be above or behind the saw blade. Should kickback occur, the hands and arms can be pulled into the saw blade. Serious personal injury could result.

Always use push sticks, featherboards, push paddles and other safety accessories whenever possible to increase safety and control during operations which require the blade guard and splitter to be removed from the saw. Failure to follow this warning could result in serious personal injury.

4. Turn the saw on.

5. When the blade has reached full speed, perform a test cut with a scrap piece of wood.

6. If the cut is satisfactory, repeat with your finish stock.

WARNING

Always turn the saw off and wait until the blade has come to a complete stop before adjusting the fence. Failure to follow this warning could result in serious personal injury.

7. Rotate the workpiece as shown in Figure 38.

Figure 38. Rabbet cutting.

8. Perform the second cut to complete the rabbet cut.

Always replace the blade guard after dadoing is complete. Failure to follow this warning could result in serious personal injury.