Today I adjusted the saw to a perfect 90 degree angle to the blade to make sure that I have very nice right angle cuts. I used one of the machined mounting blocks which I have from my machinist for the trailing arm hanger. These blocks are absolutely perfectly square and ideal for the job.

Having done that I realised that this angle is ok to adjust without additional tools but the other problem is the vertical angle. Over a length of 9m a minimal angle away from a perfect horizontal level will result in a not so perfect vertical cut. Using a normal bubble level and eyeballing it will not be good enough for those cuts where we want a perfect right angle in both directions. This is particularly important for the cross members which sit against the main rail and we want them to be perfectly square, which makes squaring up the whole chassis so much easier.

Tomorrow I get a laser level with a tolerance of 0.05 degrees and I can level the saw and the beam to a near perfect level for maximu accuracy, at least what I can achieve with amateur means.

I also have made a little video that one can see the saw working. I had it set to 0.5 – 1mm per minute (roughly) so the 76×76 took somewhere between 12 and 15 minutes. The big beams will take longer, but the cuts are really perfectly smooth at this speed. The good thing is that the machine stops at the end automatically, so I do not have to be there all the time. Setup at the start and then I can do other tasks and let the saw do its thing.

 

Above is the embedded movie file.

Today (26.3.) I started in ernest after I got my electronic laser level. Levelling the saw in both horizontal directions and then levelling the beam is essential for a perfet 90 degree cut. With the electronic level there is no guessing anymore especially with 9m long beams where a minimal angle will change the cut angle quite a bit.

saw_level

beam_level

With a little patience and slow speed the cuts are absolutely perfect. No way you could do this commercially, one needs a good precision drop saw for that, but mine is not big enough for those beams, so I am happy to do it this way. The saw runs by itself and shuts off automatically once the cut is finished.