snip
That's a lot of work with the leg system. I'd never heard of it, nor
did I ever think the legs were a problem on mine while I had it.

-- One of the biggest additions - I ditched the old fence and have
installed a new Align-a-rip 24/24 fence. WOW, I realize it's not an
Incra, but compared to the original fence it's wonderful. I was going
to align it to be 12/36 but didn't have the room so it's still 24/24



Good idea. I did that, but I'm not sure the improvement was all that
significant. It's the steel pulleys I did at the same time that was
more useful. The cast pulleys were obviously well worn on mine by the
time I did it.

-- I'll be adding an overhead blade guard - I have parts cut out of
3/8" Lexan they just need to be assembled for the guard, then I'll need
to do the armature for the overhead assembly. (this one should be done
inside a week or so)

Like a Shark Guard? You're obviously going for dust collection. I
never felt it was worthwhile on this saw.

-- I also want to close in the back of the saw to improve dust
collection -- (I'm looking for suggestion on what the best way to close
it in btw.)

Have you added (or plan to) a zero clearance insert or PALS system?
The zero clearance was nice, but my saw held it's alignment pretty
good, I never felt I needed the PALS.

My saw is gone now, but with upgrades like the ones you're doing, it
becomes pretty fair.

Ultimately, I sold mine and got a saw with more power and didn't
require extraordinary effort to adapt for dust collection.




I'm actually skipping the dust collection on the guard... The
collector on the bottom should be enough... With this one I liked the
almost bullet proofness of the design and the visibility, plus I liked
how easy it was to move out of the way with the overhead design. I'll
get some pics of it up after I assemble it.

When I had the saw up originally it had a fair amount of wobble/twist
to it. It wasn't to the point of collapse, just more than I liked.
Seemed that they should have used just a little heavier steel when
doing the legs. With the bracing it's solid now.

The saw also sits on a heavy rubber mat now too... (not sure how clear
that is in the pics), my shop floor is a nightmare of angles, when it
was poured the folks who did it sloped everything to the drain in the
middle of the floor and when I say sloped, I mean SLOPED. The entire
floor is almost like a funnel. Thus the wood under the rear legs. I'm
going to make something more permanent in short order.

I was going to do the PALS but wanted to see how it held before I
installed them. I'd seen a few folks say pretty much what you did and
figured it wasn't a must do.

The zero insert is on the plans, forgot to include that...

The machined pully set is coming too...