I took a cast aluminum duplex outlet box and added 10 feet of 12/3 rubber covered wire with a high quality closed face three conductor plug to it. I wired this cord to a high quality duplex outlet with a cover. I then plugged the Sears Automatic Power Switch into the duplex outlet. Next, I took a 3/4” wide by 12” long by .031” thick piece of brass strip and wrapped it around the switch and down to the sides of the outlet box. I had previously drilled a 1/4” hole in each end of the brass strip. I marked the location of the holes on the sides of the outlet box and drilled and tapped them to accept a 1/4”x20 bolt. After cleaning out the outlet box, I reassembled everything and bolted the brass strip to the outlet box with short bolts. I also mounted a magnetic surface mount plate to the bottom of the outlet box so I can position the switch on the stand or the side of the saw.
Since my saw is out of warranty, I shortened the saw’s power cord from 11’ to 3’ to reduce any voltage drop that might come from plugging the saw into the extension cord. I only have one power cord on the floor now, my shop vac turns on every time I turn the saw on, and the switch stays put without pulling out of the outlet it’s plugged into. I also now have a heavy duty, low voltage loss, tool triggered extension cord for use with other tools in my shop or outside. The pictures below should give the reader a good understanding of the setup and how I use it on my BT3K.
Original PDF Document:
tltrigcd.pdf