This job is moving on a bit at last. Whilst awaiting delivery of the motor bearings I decided to sort out the pin problem once and for all never wanting the hassle again trying to remove one of these pins.
I gave considerable thought to preventing the pin from turning and it wasn't an easy problem to resolve. My first thought was to make a slotted component as seen in the pictures so after carefully measuring I came up with a design and took my time cutting the new design out of mild steel sheet; the slot was formed by drilling each end then using my fretsaw with a piercing saw blade installed; this took a lot of patience but it worked; I used the hacksaw for roughing out followed by grinding and filing. There was already an hole in the yoke casting and this was a perfect diameter to accept a 6mm thread; I added a second thread diagonally opposite. The design worked and would solve the problem but having a bit of spare time for a change I wondered if I could simplify the component further?
Using the same measurements I sat at the computer and used "emachineshop" free CAD to draw very accurate templates; these were then printed and cut out with scissors; accuracy is most important whilst doing this kind of work and impatience will quickly ruin it so I took my time and enjoyed using the skills I had been taught 50 years ago. I haven't measured the steel thickness but it's certainly never going to fail. The template was secured to the steel blank using double side self adhesive tape; not the best of things to use but it was to hand.
Pilot holes were drilled followed by clearance holes ( 6.8m) to accept a 6mm locking set screw; the fretsaw was used as were the assorted files and hacksaw to produce the component; with a bit of touching up it was a nice close fit; the remains of the template were a pain to remove due to the sticky tape; all sharp edges were eased with a file then it was cleaned up with abrasive paper.
I added plenty of holes for adjustment and it fitted perfectly; a 6mm set screw was cut to length and a strong 6mm spring washer would prevent the set screw working loose.
These two components look very simple indeed but they were far from simple to dream up and put into practice; removing the wayward pin is now extremely easy; just remove the set screw and the pin is out in seconds; I filed away the locking lug on the yoke casting it no longer being required. It was nice to use my head and hands once again keeping my old skills alive.
I'm used to designing and making things in fact it's something I enjoy doing but at the moment the garage is a tip whilst I'm remodelling it so this made the work a lot more difficult; I used hand tools apart from drilling the holes to show what can be achieved; I could have turned the circular component on the lathe and I could also have cut the slot on the lathe but this would have removed a lot of the fun in the making. I spent many hours trying to come up with an alternative solution to preventing the pin from turning and I can now understand Mr DeWalt's dilemma coming up with his own solution.
The new bearings arrived a short while ago for the motor so tomorrow I'll reassemble the motor then I can sort out the lethal electrics.
Whilst at Rufforth Auto Jumble last week I bought what I thought was a Start/Stop push button station costing £10 thinking this to be a standard switch where the start button is open and the stop button is closed but how wrong could I be? I checked it with my DMM multimeter and couldn't get any sense out of it at all; I've checked the station on the web and find I've actually bought a very good KEDU KJD17 no volt release starter switch; I'm not surprised I couldn't obtain the readings I expected whilst testing it. I intended to install a proper DOL starter but this new station will be fine; the saw's original switch is merely a two pole switch either on or off and no way was I going to use this on its own; such a switch between power supply and motor is just asking for a serious accident because if the power went off the switch would still remain on resulting in the saw spinning up as soon as power was back on; this new station will prevent this from happening so I'll be happy to install it; I've seen these two button stations many times but never handled one; I've always used DOL starters so this station is new to me; here's a bit of useful information;
http://www.axminster.co.uk/kedu-kjd17-n ... 1ph-950700
Kind regards, Col.
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) It would be real handy to be able to cut housings in one pass for cabinet work. You can get them from the States for around £60 odd. 
