KCW Innovation: Custom Kick-Stop Switch
A visit to any craftsperson’s shop is always a curious glimpse into the maker's mind, allowing one to visualize the entirety of the space as a tool—a highly customized instrument. If you look closer you’ll find this on the micro level, culminating in modified tools and jigs. I imagine all serious makers inevitably modify a tool or two, whether it be for ease of use, safety, or some other external force; modifying a tool must be ingrained in the journey of using it. At the core, the day-to-day use will modify its nature, its sharpness, so customization is truly an unavoidable constant of the profession.
I was recently approached by our shop manager, Eric Swanson, to make a modification to the KCW floor. Eric’s vast shop experience, and in this case table saw experience, catalyzed a vision for a safety feature design which he had built for previous saws. Eric understands many of the challenges and work flows associated with a production table saw, and he presented a time-tested “Kick-Stop” or “Kick Switch” design which would allow the use of a large target pad to be kicked as an "off" switch. It would need to be seamless with the saw, adding safety without compromising ease or efficiency.
The design Eric had implemented years ago used two actuating arms linked from the kick pad to press the power switch. The concept we implemented at KCB is basically the same, with minor design differences. We started the process by observing and analyzing the task flow of all the builders actively using the saw. Where do they move their feet when finishing a cut? How do they naturally align on the saw during a rip? Our instrument at hand is a 1970’s belt driven SCMI table saw which gets used by everyone for everything—rough ripping 15-foot material, to cross-cutting final lengths of cabinetry and other fine woodwork. It's safe to say this modification would need to be as proven as the saw itself.
These crucial observations of our user base helped us place mock-ups of the target pad and actuating arms. From this, I drew concept sketches exploring the hinging mechanics and mounting challenges to the SCMI. With the design chosen, I built a full bench mock-up and tweaked the tolerances of the parts in order to anchor the mechanism as close to the saw as possible.
The arm and pad designs use threaded inserts for linkage adjustments and are machined from laminated baltic birch plywood, detailed and finished, to match the language of the 50 year old Italian saw. I transcribed the bracket layout to the final locations and had an existential pause before drilling into the old steel cast, reminding myself I was merely sharpening the tool.
As I’ve monitored the wear on the modification over the past three months, the team has transitioned to using it as the main “off” switch. I designed it and planned for that much use, but I underestimated the positive effect it would have on the system as a whole. It was an honor taking on this challenge while experiencing a successful process improvement. For me it represents KCB’s dedication to a higher quality of work derived from customization. We make custom woodwork: it's only natural the tools adapt to keep up.
