Table Saw Upgrade
Rebuilt a Powermatic 66 with new bearings, fresh paint, a 3 HP motor, custom storage, outfeed table, router table extension, improved dust collection, and upgraded fence and miter system. Now runs like a brand‑new saw.
Background I had been using a Delta 1.5 HP contractor saw for years, but when I found a Powermatic 66 worth rebuilding, I decided to upgrade. The saw needed work, but the bones were solid — and the end result turned out better than new.
Mechanical Rebuild I tore the saw down completely and:
Replaced all the bearings
Installed a 3 HP motor
Stripped the cabinet to bare metal
Repainted it using an HVLP sprayer for a factory‑level finish
Added leveling feet for stability
The cabinet originally had no bottom, so I welded in a steel floor to keep sawdust from dumping onto the shop floor.
Dust Collection Improvements I designed and 3D‑printed a dust‑collection chute that captures dust right off the blade. After some adjustments to clear the 45° blade tilt, it works extremely well — about 90% of the dust now goes straight to the collector.
Cast Iron Top & Extensions I polished the cast‑iron top using an angle grinder with fine polishing pads, followed by a felt pad and compound. After waxing, boards glide across it effortlessly.
I added:
A cast‑iron router table extension
A Harvey sliding miter gauge that mounts in place of the left extension
The original left extension moved to the right side
About 43 inches of rip capacity with the new layout
Fence System I always liked the Unifence on my Delta, so I removed it and mounted it on the Powermatic. I also bought a second, longer square fence with accessory slots so I can adjust the setup depending on the length of the boards I’m cutting.
Storage & Outfeed I built a custom storage cabinet under the saw for blades, jigs, and accessories, and added a full outfeed table. My old router table is now part of the outfeed, with a new top to replace the one that sagged after years of holding a router.
Result The saw looks and performs like a brand‑new machine — powerful, accurate, smooth, and fully customized for the way I work. It’s one of the most satisfying shop upgrades I’ve done.
