Non SD: Circular Saw Magnesium Shoe

Sarasota_Steve

Sarasota_Steve

Hello,

I tried looking for answers online and found none so I thought I might be able to pick the brain of our smarter members and get an answer here.

I own a Dewalt circular saw DWS535 with a Magnesium shoe. I do not use it for work or heavy use. I built a deck and some other miscellaneous jobs around the house. I bought this worm saw because of the brand name and their claim that is construction grade and should last a lifetime. I like good quality tools. The other thing that attracted me to this saw is that the blade is on the left side and being right handed, I can see where I'm cutting.

I used is this past weekend and the shoe plate was bent so it does not make full contact on the work piece and wobbles. I bought another shoe ($53) and installed it. The old shoe, can it be bent back into flatness? Again, it's magnesium so it's very light weight but it was supposed to be very strong also.

I clamped it to my workbench for 2 days and when I un-clamped it it went back to being uneven. Should I use heat?

I'd like to straighten it in case the new part bends like the old one did.

Thank you for your input.



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Sarasota_Steve

Sarasota_Steve

You are going to hate this but the answer is yes and no
It is caused because the plate is cast (read cheap to manufacture) and has stress relieved because of the web thickness design on the back to make it less flexible/stronger for a given mass. ie -uneven distribution of metal through the cross section of the part!
Now if the plate only has a slight bend in it you might be able to bend it back but the problem is that to bend it back you have to go past the flexible limit of the material and that is where it might work or it might not. Cast materials usually dont like to be forced into bend moments and yield quickly without any indication.
You can try but I think it will likely crack. You could try heating it to the malleable temp but being Magnesium it could just catch fire depending on the magnesium content especially if heating with a naked flame
Your other choices are:
cover the bent face in metel set epoxy and sand it back flat
screw a thick piece of marine ply to the plate and epoxy in position whilst clamped to something flat - this will obviously reduce the depth of cut available.
take it to a joiner shop and ask them to put in on their large belt sanders and take it back to flat
take it to a machine shop and have them reface it.
If you were just down the road from me I would sort it for you in 15 minutes

EDIT- if you want the new part to stay flat and not do as the original (very likely) then just fill all those pockets on the back with epoxy and allow to dry whilst it is being clamped down flat - that will help keep it more supported over the long term and reduce the stress relieving going on.
Happy playing