This is a replacement handle I designed for my Craftsman table saw. My old one broke and I couldn't get it glued back together! Similar parts sell for somewhere between 15-35 bucks online. Also will work with an Ace branded 10" table saw.
Scale note: I'm a newb and created this with the scale set to 1=1cm instead of 1=1mm, so you may need to scale up the print 1000% in your slicer. (It's what I did.)
Printed with 50% infill, Prusa i3 MK3, PLA, make sure to ask slicer to print support material!
The bottom looks a little gnarly since it is trying to print a horizontal suspended surface, but it sort of adds to the rustic charm.
I reused the threaded knob from the original handle, I believe the nut is 7/16" coarse thread. (17.2mm width, 9.45mm depth) ... it fit like a glove. I'm pretty impressed with myself.
- I made the flat face on the front of the wheel less pronounced
- I increased the amount of chamfer on the bolt hole
- Thicker spokes
- I needed more clearance between the wheel and the front of the table saw, so I moved the wheel another 4-6mm "forward"
- I made the barrel/base of the handle 4-6mm thinner, so that the springloaded mounting shaft would reach all the way through the part. (Oops.)
- I moved the wheel forward yet another 6mm to give enough clearance for a screw lock that is located behind the wheel. This also increases the angle of the spokes so they print cleaner and look less gnarly.
- I made the resting place for the T-pin a little bit skinnier to ensure there was less play in the handle
- I added gear teeth to the back end of the handle, which can be used to adjust the angle of the table saw (when the aforementioned screw lock is loosened)
- I added some distance to the front of the base so that the washer and nut on the front of the handle tightened more securely
- Gear teeth! This turns the angle of the saw blade when you push in and turn.
- Curved spokes like the original part! Now it actually fits properly on the table saw and has clearance over the release screw that sits behind the wheel. Sort of a wonky design.
Tweaks I may make in the future:
- I should cut in some "up / down" text into the front of the wheel like the original
- I'm not sure if there's a good way to make the front of the handle more aesthetically pleasing other than making it a flat-front print. I'll noodle on that. I also don't want to use multiple parts for structural integrity reasons.
Comments welcome, if you print one, show me how it turns out!