DW788 Woes

[Marsha]

Now that my problem with my PM's has been fixed, I have a worse problem.
MY SAW WENT FOR A CRAP. While finishing up my clock face on Wednesday, the tension on the saw would not hold. I took the tension mechanism apart and it appears the threads in the lid cover are stripped, and a small piece of aluminum peeled off and got stuck in the tension lever. I took the part to the repair shop so they could order me a new one, it should be here by the end of next week. So I quess I'm out of commission for awhile.
This is the lid cover that needs to be replaced
Blade tensioning cover0003.jpg
The bolt hole is elongated so I'm thinking maybe it's been loose for awhile.
Anyone else had a problem like this
Marsha

[Daryl185]

wow Marsha I know that really blows I have had the cover off a few times but have never experienced a problem lkie this but its good know about this as its easy enough to check

[lucky788scroller]

I havent ever had a problem with that.When you put tension on the blade, did it tighten, then go loose as you started to cut, or just do nothing when you tensioned?
Bill Y has an old Dewalt, perhaps he might be willing to sell it cheap,it wouldnt hurt to have a parts saw for emergencies like this, and its pretty much useless to him now anyways. Dale

[William Young]

Dale.
I sold mine for $100.00 over three years ago after the knocking could no longer be stopped without major surgery and just about every other part on the saw was worn out. I never replaced the part that Marsha is showing but I did have to replace the part that the tensioning handle is connected to because it was just cheap pot metal and wouldn't hold tension against the little roller under it. I ordered that part when it just started to let go and by time the replacement part arrived over a month later I had the tension handle tied back with a piece of thin nylon rope in order to keep sawing.

I explained fully to the very old gentleman that bought mine that it's days were numbered and he didn't mind the knocking noise that could no longer be repaired after several successful attempts about 6 months apart each time. He also didn't mind that the speed would vary up and down on its own because the VS controller was on its last legs.
I meet him at the coffee shop sometimes and he says he spends less than a couple hours a year on it so it will last a lot longer than he will even in the condition it is in. .

Don't take me wrong , I am not raking DeWalt over the coals as I am so often accused of. I would imagine that saw cut more wood in it's short three years lifespan than anyone else's DeWalt saw on this site regardless of how long they have had theirs. It paid for itself many times over with all the clocks that I used to make out of solid oak and most of it was deep stack sawing.

W.Y.
(edited for typos and spell check)

[Marsha]

Dale, the tension would hold for a few minutes of cutting and then let loose. The bolt that goes through the tension lever and into the lid holding the entire unit together, would not go down tight, it stopped about 1/2 way. I quess as I sawed the bolt worked it's way loose causing the tension to let go. I took the entire unit to the repair shop, they examined it carefully and decided the only part I need to replace is the lid cover. Total cost $ 15.00 not really a big deal, except I'm sitting idle right now.

Bill, I don't think you're bashing Dewalt, it's always helpful to hear other people's problems. Your Dewalt was very good to you and I hope my last as long.

The DW788 is a very good saw, at least the Type 1. If I hadn't got my hands on one, I probably wouldn't be scrolling, the Delta I had was a PITA when trying to do fretwork, and I found the blade changing a nightmare.
Marsha

[Marsha]

Well, my saw's still out of commission. I just called the repair shop, and the part is still not in. These people just don't know how frustrating it is to be without your saw. What do you do in the mean time?
I have some beautiful cherry wood just sittin around waiting to be made into a box, and some really nice lacewood for ornaments. I also have the Sue Mey clock half cut, this was going to be my donation to the Prader Willie walkathon. I doubt I'll get it finished on time now.
I think I'll go out and clean the shop, one more time. Maybe see if I can get the old Delta running.
Thanks for listening
Marsha

[Trout]

hang in there...we're here for you.....

Trout

[bobledoux]

I'd take the existing part to an auto engine machine shop and ask them to insert a helicoil. The current hole is drilled larger and a steel insert is screwed into place. The inside of the insert has the threads that replace those that have stripped. This prevents the problem from occurring again. They have to know the size of the thread in the bolt, so take the bolt.

This looks like a possibility. It might even be cheaper than a replacement part. Its worth a try.

[William Young]

Marsha;
Sorry to hear you are still waiting for a part. I was really hoping that DeWalt parts availability would be better out east than they are out west here.
In your original message when you said

I took the part to the repair shop so they could order me a new one, it should be here by the end of next week.

I was thinking more like a month would be the norm.
And now since DeWalt are part of Black and Decker I have heard that parts replacements and customer service is even worse.

Hang in there. The part will come eventually but you may have to contact them a few more times and say you really need the part.
W.Y.

[Marsha]

Originally Posted by bobledoux

I'd take the existing part to an auto engine machine shop and ask them to insert a helicoil. The current hole is drilled larger and a steel insert is screwed into place. The inside of the insert has the threads that replace those that have stripped. This prevents the problem from occurring again. They have to know the size of the thread in the bolt, so take the bolt.

This looks like a possibility. It might even be cheaper than a replacement part. Its worth a try.

This does look like a possibility, being in the heavy metal welding business, I know a couple of very good machine shops and I will take the part to them to see if they can help me out. Actually my hubby and I were discussing this over the weekend, I said I would give the repair shop 1 more week, then go get my money back, but I think I'll do it sooner, especially in light of what Bill Young said in the post right after yours.
Thanks alot for your concerns and suggestions
Marsha