Metal Cutting Saw

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Thanks for the note. I think bridge saws would be a good bet for this. I looked at them before settling on the old RAS. Many use a high speed (5000rpm) motor. I did find a bridge saw sold by Harbor Freight and Northern Tool that is under $300 and uses a 3500rpm motor and looked at that a couple times. It has good reviews. Would have had to use table extensions on both sides. The RAS with long table came up on Craigslist while I was still trying to decide so got that instead of a bridge saw.

 

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On dadoing which seems to be one of the best uses for the RAS. Last year I rebuilt the deck at our Virginia house which entailed 62 4x4 posts dadoed for 2x4 rails top and bottom. That's a lot of big dados. Used my table saw with sliding top and extended miter gauge and a new dado blade. The regular saw fence made a stop for the left side of the dado, and a clamped block on the miter gauge made a stop for the right side of the dado. then hog out what's left in the middle. that gave perfect sized dados every time with no measuring and no lining up of the blade. In the past I used the same kind of stopping setup on a RAS, but the table saw is much easier to use, no fighting of the blade.

 

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Last update on saw - I think it is done now. I've taken up all ideas and suggestions. I was thinking of rubber flaps, and JJ suggested a magnet. Combined the two ideas in a flexible rubber magnet material sold by McMaster Carr. See picture. It works great to capture and also control chips. Also routed a slot for the blade to travel in. Interestingly it results in virtually all chips being ejected forward, the picture shows the chip pattern. Upgraded to an 8 inch Milwaukee metal cutting blade, it is quieter and smoother than the Makita 5 3/8 inch blade. Also upgraded the hold downs to use 3/8 inch studs. And contoured the ^%$# thrust plate so I don't cut myself every time I reach for the hand wheel. Thanks to all for suggestions, it is a much better tool now. The cut is good. In the camera flash you can see a pattern but it is completely smooth to the touch, similar to a milling machine pattern.

And I have a lifetime supply of magnetic rubber, it is sold in 5 ft rolls, if anyone wants some just say the word!