Record Power AC400 PCB Upgrade

I've just received a new PCB for the AC400 Air Cleaner from the excellent people at Record Power. Their customer service department is fantastic. As recently reported in my blog back in December 2014 an issue had been identified with the Mark I and Mark II PCBs which could cause overheating. In fact I had already had a Mark I board burn out. This was replaced as part of RPs 5 year warranty.

The new PCB module came yesterday with full instructions on how to fit it. There were a number of screws to remove to gain access to the motor module and PCB module. A couple of 5.5mm nuts hold the PCB in place and two push in connectors make the electrical connection.

Mark II PCB on the left
Mark III PCB on the right

MusicMaking Gear

Here's a few musical instruments, amplifiers, effects and recording gear at Casa TMc

Dunluce Rapter Synth guitar, Tanglewood acoustic, TMc TCaster, TMc Lapsteel, Fender F-03 Acoustic

Knock down saw horses and low assembly table - Part 2

So here are my finished knock down saw horses in a few different configurations. All the edges have a 1/4" roundover.

Saw horses without crossmembers
They just work like a pair of regular saw horse

Knock down saw horses and low assembly table - Part 1

When cutting up large sheets of material, plywood, MDF etc., it is always better to break them down at a lower level (to prevent back problems) and with a circular saw (Festool track saw or even just a circular saw with a guide).
I saw the design for this a few years ago and redesigned it from memory. I didn't have much difficulty in remembering the design as it is so simple. Essentially it comprises 4 legs, 3 long sections and 3 cross members. It is possible to obtain all the parts from a single sheet of 8' x 4' x 18mm (3/4" nominal) plywood. I used external hardwood plywood as it is easily obtainable from a home centre. This will support a full sheet of 8' x 4' with no problem.

I can't remember the original inspiration for this design so apologies if it was you.

First of all I designed it on Sketchup and came up with this.

One possible assembly

Zero Clearance Inserts

The Record Power TS250 table saw doesn't have the best of dust collection. This is compounded by having enough space between the blade and the sliding table to pass slivers of cut-offs into the dust collection shroud under the table. This blocks the airflow in time and cuts down on the already inefficient dust collection.
Obviously the stock aluminium insert is designed so that the blade can be tilted up to 45 degrees. However most of the time I do 90 degree cuts. So I've been replenishing my supplies of zero clearance inserts. These are just plywood with a slot cut in and 3 countersunk holes.

To make them you need to cut the plywood to width and length. Next using the aluminium insert as a guide transfer the holes through into the plywood. Then countersink to the size of the screw used.

Remove the riving knife and put in the desired blade - this is the only time I advocate removing the riving knife - always operate your saw with a riving knife or splitter. In my case it is a 80 tooth blade for cutting man made materials. Bolt the insert down to the opening and cover with some masking tape or blue tape. Switch on the dust collector and power up the saw.
Then carefully raise the blade so it starts cutting through the insert. Raise it all the way until you run out of stroke on the raising mechanism. Switch off and retract the blade.

Next you will have to extend the slot to suit the riving knife. Mark the position of the rear of the riving knife on the insert. Then reposition the insert (without screws) about another 100mm forward towards the operator. Then stick the insert down with some more blue tape.
Switch on the dist collector and raise the blade again. This time watch for the rising blade just kissing the pencil mark you made.

The insert is complete and you can then screw it down in position after first reinstalling the riving knife. Give it a coat of paste wax, especially on the slot sides, and you are good to go.

Finished Insert

Room for blade and riving knife