jigsaw window

peterm · Post by **peterm** » Sat Feb 20, 2010 8:54 pm

I was concerned about oil level in my jigsaw because it has some slight leaks so I applied an idea I first saw in the 4x6 metal cutting bandsaw Yahoo group, namely, to install a plastic window in place of the cast metal drive cover. Works great. Using a led flashlight, I can see the oil fill bolt in the back of the casing to check if the oil is still up to the bottom of it. A similar window on my 4x6 was installed over a year ago and has not been affected by the oil. See the attached picture.
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billmayo · Post by **billmayo** » Sat Feb 20, 2010 10:24 pm

prmindartmouth wrote:I was concerned about oil level in my jigsaw because it has some slight leaks so I applied an idea I first saw in the 4x6 metal cutting bandsaw Yahoo group, namely, to install a plastic window in place of the cast metal drive cover. Works great. A similar window on my 4x6 was installed over a year ago and has not been affected by the oil. See the attached picture.

Thanks. An excellant idea as every jigsaw I get to repair has no oil left in the housing. Is the material you used just clear plastic? What thickness did you use? What material did you use for the gasket? I find the original gasket slowly seeps oil over time. I will make up a few of these covers to test different gasket materials I have used. I will see if I can scribe a level line on the outside of the cover for the correct oil level so it is really easy to check. Thanks again for an excellant idea.

cincinnati · Post by **cincinnati** » Sat Feb 20, 2010 10:35 pm

I once owned a motorcycle that had a clear site glass window about the size of a nickel that would show the oil level. Wonder what on could use to make on for the jigsaw.
Something like this.

easterngray · Post by **easterngray** » Sat Feb 20, 2010 11:30 pm

What a great idea. Thanks a bunch!

JPG · Post by **JPG** » Sun Feb 21, 2010 12:02 am

prmindartmouth wrote:I was concerned about oil level in my jigsaw because it has some slight leaks so I applied an idea I first saw in the 4x6 metal cutting bandsaw Yahoo group, namely, to install a plastic window in place of the cast metal drive cover. Works great. A similar window on my 4x6 was installed over a year ago and has not been affected by the oil. See the attached picture.

Excellent idea!

Please explain the '4x6'!

peterm · Post by **peterm** » Sun Feb 21, 2010 6:33 am

Thanks for your comments.
Bill, the plastic is 0.20 inches thick. It was cut out of a plastic shelf that was originally part of a store display. It cuts without chipping on the bandsaw using a fine blade and drills like cheese; sorry I don't know the type of plastic. I used 0.625 inch diameter by 0.06 inch thick washers to spread the load of the screws. The screws were cut from longer ones at about 0.53 inch thread length to replace the originals. The gasket was made by scanning the original into my computer and printing it exact size onto a large label, which was then stuck on a piece of cardboard cut from the kind of gift box that shirts or ties come in. A cereal box would likely be similar card. I just cut it out with a box knife and punched the screw holes. I left the label on the cardboard. I think it does still weep oil slightly but so little that it does not matter now that I can see the level. A scan of the gasket is attached. I had to resize it from 852x852 pixels to 600x600 so you may have to put it back to get it to print the correct size.

Peter in Dartmouth NS

peterm · Post by **peterm** » Sun Feb 21, 2010 6:36 am

JPG
The 4x6 refers to the 4"x6" size that type of saw can cut. It is the common term for those cheap (around $200) metal cutting bandsaws.
Peter in Dartmouth NS

robinson46176 · Post by **robinson46176** » Sun Feb 21, 2010 8:34 am

billmayo wrote:Thanks. An excellant idea as every jigsaw I get to repair has no oil left in the housing. Is the material you used just clear plastic? What thickness did you use? What material did you use for the gasket? I find the original gasket slowly seeps oil over time. I will make up a few of these covers to test different gasket materials I have used. I will see if I can scribe a level line on the outside of the cover for the correct oil level so it is really easy to check. Thanks again for an excellant idea.

Yes this is a great idea. It occurs to me that if I do this I might retain the original cover with a large hole in the center of it. It could then provide more clamping support for the perimeter of the clear plastic. I might also substitute Automotive RTV silicon sealer (probably high temp red) for the paper gasket.
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That looks so cool that you will want to be sure you don't get a finger cut from bending over watching the saw work and not watching the cut.

JPG · Post by **JPG** » Sun Feb 21, 2010 2:16 pm

'Lexan' would probably be a good choice. The cast cover makes an excellent template for the gasket. Auto supply stores sell gasket material by the sheet and is inexpensive. When making the gasket do not overlook the need to provide an air path for the vent(that is the reason for the cloverleaf around the mounting holes).

djwatts40 · Post by **djwatts40** » Mon Feb 22, 2010 9:21 pm

Talk about great minds, I was just designing a similar cover for myself so will share. My plastic is Lexan, but about 3/16" thick. I have included a hole near the top of the cover with threads for a 1/8" pipe plug. A 1/4 - 20 machine screw with a washer and an o-ring for a seal would probably work as well. The reason for the hole is so I can add oil without having it back out of the existing fill hole when it is full.

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