DeWalt™ DWE7492 better tilting mechanism by WK_2033

Last crawled date: 3 years, 4 months ago

I bought the "new" DeWalt DWE7492 table saw because many reviews hyped it as the new GTS10XC-Killer. In fact the saw is really great regarding the fence system and the height adjustment of the blade.
The only thing that really annoyed me after using it for a while was the tilting meachnism.
As soon as you loosen the clamping lever the saw can be easily moved freely. But with this it is almost impossible to set the saw precisely to a certain angle, because the saw will move a bit as soon as you try to clamp the lever into position.
To get a tiliting mechanism with better useability I decided to develop a new mechanism that can be cranked to excactly the position I need. This development is not finished yet, so see this Thing as a work in progess.
The whole design consists of some 3D printed parts combined with some parts from the local hardware store.
Furthermore the whole design is made in a way it can be easily assembled and dissassembled without voiding the warranty (in case your saw is as new as mine).
There are two sets of brackets. One for the left side, holding a 25mm square steel tube and some ball bearings for the cranking mechanism. And one for the right side supporting the square steel tube and the axle for the worm gear.
The gear has an overall reduction of exactly 1turn per degree.
At the moment the worm gear needs some support to stay in place. This is accomplished by multiple parts that were glued together with "Tangit PVC-U plus" .A future design could probably combine these four parts into one (or at least provide some clever mechanism for alignment).
Edit 11.10.2020:
The worm gear was redesigned and combines now the gear and the support structure. Instead of glueing the gear and the radial support structures can now be screwed together.
The top of the Worm gear will not touch the housing of the Saw. This was designed on purpose to add a screw to the top hole which can adjust the final distance to the housing. This is very important when the saw is tilted to 45° as the weight of the saw will create so much pressure on the gears that the tend to slip if not aligned properly.
Parts needed :
Left side:
1x DWE7492_RestLeftInner.stl
1x DWE7492_RestLeftOuter.stl
1x DWE7492_Crank.stl
1x DWE7492_SpurGear_12T.stl
3x Ball Bearing 608
2x Cylindric Screw M4x70
2x Cylindric Screw M4x45
4x Nut M4
1x Threaded Rod M8 (approx 140mm long)
1x Screw M3x30 (for 12 teeth gear)
1x Nut M3
2x Washer M3
Some M8 nuts and washers
1x Screw M8xXX (as handle for the crank)
Right side:
1x DWE7492_Rest_right1.stl
1x DWE7492_Rest_right2.stl
4x Screw M4x30mm
4x Nut M4
4x Washer M4
1x Ball Bearing 608
Worm axle and axle support
1x Square steel tube 25x25x1,5 ~600mm long
1x DWE7492_Worm_v1.stl
2x DWE492_WormAxleSupport.stl
2x Ball bearing 608
9x Nut M8
9x Washer M8
1x Threaded Rod M8 (~600mm long)
Worm gear:
1x DWE7492_WormGear_V5.stl
2x DWE7492_RadialWormGearSupport_V2.stl
2x DWE7492_Clamp.stl
4x Screw M4x50mm
4x Nut M4
8x Washer M4