Trading your chop saw base for something shop built

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We've got a Dewalt 14" chop saw that's probably over 10 years old. We have it mounted on the side of our welding table which seems to work pretty well. Just as most people who use chop saws have experienced, the blades do tend to flex as you're making a cut.I got to looking more closely and talking to the local welding shop and have discovered that the blade of the chop saw is not anywhere close to perpendicular to the base of the chop saw.I removed the two bolts that hold the chop saw to the base and inserted a shim under the left one and then put it back together. Much closer to perpendicular, but still not perfect. Now that it's coming down close to straight, the blade does not flex nearly as much and I get a much better cut.So, with all that being said, I'm wondering if any of you have made a real base for your chop saw. You know, the kind that has a vice that will actually keep things from moving, the kind that ensures the blade always comes down exactly perpendicular to the piece that is being cut, and maybe even one that pivots so that your work can stay in the same position laterally while you change the angle of your cuts.I just have this feeling that all the complaints everyone has about chop saws being inaccurate are more closely related to poorly designed bases than they are to flexible blades. Anyone care to share their quest for making an accurate chop saw? Thanks.
Reply:My experience is that it'll help some. However the biggest help is by going to a thicker blade like 1/8" instead of the thin ones. However the rub there is that you've got to have the horse power to run the thicker blade properly. My old home made chop saw did well with 16" 1/8" thick blades once I got a big enough motor on it. The miter chop saw I have now works fair with the thin blades but much better with the thick.Millermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:Here is the base I made for my DeWalt Multicutter. The thin 14" abrasive blades flex, and there is no real cure for it except to clean up with a grinder. I have an 18" saw that uses much thicker blades and is dead accurate. Also, the cold saws are much more accurate than the abrasives with little or no burr.http://shopfloortalk.com/forums/showthread.php?t=28137
Reply:Originally Posted by walkerHere is the base I made for my DeWalt Multicutter. The thin 14" abrasive blades flex, and there is no real cure for it except to clean up with a grinder. I have an 18" saw that uses much thicker blades and is dead accurate. Also, the cold saws are much more accurate than the abrasives with little or no burr.http://shopfloortalk.com/forums/showthread.php?t=28137
Reply:I have a 12 ft long welding table that serves multiple functions. On the far right side, I cut a slit in the table and mounted my chop saw to the table (minus its old base) and I can lay material flat on the table and chop it off. Works great. I had to make some parts for it to all work together but it has worked for several years.Granthttp://jackalopefab.com/MM210Synchrowave 200DXMiller XMT350 w/60series feederMiller Bobcat 250 with SGA 100 and spoolgunHTP PlasmaFull Machine shop with everything
Reply:I have the DeWalt dry cut and my biggest problem with that saw is the clamping setup.  When you look at the high end cold saws, the clamping mechanism is solid and doesn't move.  The head moves to make the cut.  Mine cuts 90s fine, but when I set the fence for a 45, the clamp screw is in the same spot, so it's trying to hold the work at a 45 while the blade is pulling the piece towards itself as it cuts.  I want to redesign the clamp table out of 1/2" plate to always keep the clamping sides directly across from each other.  I think it would make the cuts considerably better.
Reply:How many miter saws for wood do you see that have the clamping surface move? if it ain't broke don't fix it. If I were to buy a different chop saw, I wouldn't get one where the "vise" moved. I've got an Evo Rage 3, and I think it's great. haven't had any deflection issues, but then again, the saw moves, not the clamping surface.There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:I always thought the clamping on chop saws sucked. My Startrite cold saw has an excellent clamp but then again, the clamp itself does not move. It is the rest of the saw that moves;-)Granthttp://jackalopefab.com/MM210Synchrowave 200DXMiller XMT350 w/60series feederMiller Bobcat 250 with SGA 100 and spoolgunHTP PlasmaFull Machine shop with everything