Model 500 extension table on studs

[reible]

Now that I have a vested interest in the 500 version again you will be seeing a few related posts. This is nothing new but still with new people coming here all the time it could be we have some that have missed this before... and besides this one is with pictures.

The extension table for the 500 uses spacers to get it lined up with the main table. You add/remove washers until you get it right. Do some adjusting to the main table and it is back to the extension table to align it again. Since the spacer/washers only come in certain thickness it can become difficult to get it "perfect".

When shopsmith introduced the 505/510 models they went with a new system using studs mounted in the extension table and a system of nuts and washers for a better alignment experence. Not wanted to be left behind it was clear that this system could be adapted to the 500 and adapt we did. Well some of us anyhow.

When I upgraded my 500 to a 520 I stuck some of the old 500 parts in a box and figured maybe some day I'd part with it but being the saver I am that was never going to happen. So not tooooo long ago I decided to put together a 500 for the shop and collected what I needed to fill out the rest of the parts to get one running again. Then I decided to get another shopsmith to take up to the UP of MI so I could get some hours in while we were up there.

Now I'm trying to get some jig/fixtures and updates done for the two machines. This update is the the one in the UP, it came with the original narrow extension table. I have a spare wide table so the plan was to get it updated to the studs and take it along on the next trip.

Now on with the project.

In this first image you see the table top and "legs" after then have been separated. (In my case this happen a few years ago and the spacer/washers have since vanished in to a drawer so they are not pictured).

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In better times I would have purchased studs but at a couple of $$ per each 3/8"-16 x 3" stud I opted to cut a threaded bar. A 3 foot section of threaded rod was about $4.50ish and you can get the 4 you need and and still pay less then four studs would cost and have material left for another project.

In this next picture you can see the 4 studs with two hex nuts in a jam nut configuration. As a bonus I'll show you how I cut the studs to length later in the thread.

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Putting the studs in is not a big deal as long as you have used a grinder/file/tool you like to use to clean up the threads where they were cut. I like to do it at a grinder and then follow up with a wire brush to make sure all the little wire bits are removed. In this photo you can see it just threads in until you can't get it any farther with your fingers.

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To go the rest of the way you simple use a wrench on the top jam nut and snug up. I don't try to get it too tight as I always use a washer and nut to lock it in place anyway.

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Un-jam the nuts and remove them. When all 4 are done you are ready to to do a bunch of fun stuff with the remaining parts.

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We now go to the next post to see about that fun....

Ed

[reible]

Here we are with the 4 studs in place.

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I like to add a washer and nut when I use threaded rod as a stud. This makes sure that the stud stays in place. You may find you would rather not do it his way and I have no problem with that as this application is not very critical in this respect.

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Having fun yet?

OK here is the picture of the stack up.

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Each stud gets a nut and washer followed by the legs and then a washer and nut. Step one is to level the top with the main table. The top nut position is used to make that happen. Once that is about right you then slide the table forward/backward and twist to have it aligned with the front and side of the main table. Snug the bottom nuts and check the alignment and position and adjust as need until you have it right on. Tighten the bottom nuts and check again...

As a hint I like to put some weight on the extension table to reduce extraneous movements and it helps me to feel the adjustments are going.

Now the Bonus I mentioned. In the next post I'll show you how I cut the threaded rod into studs.

Ed

[heathicus]

My eyes have been opened! I can't believe I didn't think about this when struggling with the alignment of my extension table! Although I can see where this is going, I can't wait to actually see it go there. Looking forward to the follow up posts!

[reible]

Hi,

While there are a lot of options on how to cut the threaded rod I'll describe one of the ways I use. This method is a hand method but it goes pretty fast and works quite well. If I had a bunch to do I'd go for a powered method but for a lazy hot day and having only 4 to cut....

Let's start with an over all image of the complex setup.

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A couple of thing I want to point out in the picture. First the bar is on some scraps of 3/4" plywood so it doesn't damage the work table top. Having the two pieces make it in the same plane and easier to work with. The top "clamp" is a 2x4 clamped tight on the left side with the quick clamp as the working end. With out the right clamp tight you can move the rod to make sure it is parallel to the line on the table top thus square to the clamping area. Once you quick clamp it the rod is no longer able to move or to turn.

Adjusting the cut is done by positioning the jam nuts and washer the length of the stud plus 1/16" from the end of the rod. With the nuts jammed you then bring the second washer and set of jam nuts so that the hacksaw blade can just move between the washers plus a smidgen. Check it again after jamming the nuts then get the rod in position to begin the cutting.

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The washers act like a guide and then it is just a matter of making the cut. Keep in mind the washers will get scrapped up so they are sacrificial but I keep them for next time... And also the parts involved get rather warm so be careful when grab them after the cut....

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So now I can go back and out and finish a few more tasks before the day ends.

Ed

[easterngray]

Magnificent! Thanks alot - Can't wait to incorporate your ideas to my 500! Alec

[boostfan]

I like your method,

I bought a 10ER extension table from ebay, I plan on using the upright to mount 1 of my 520 floating tables. I was contemplating looking for studs, but this is an easy idea.