BT3000 Safer Power Switch Modification by Jim Frye

This add on to the BT3000 came about from a question on the tool forum concerning problems turning the saw off in an emergency situation. I have “missed” the switch cover many times because I was concentrating on the spinning saw blade, the work piece, the cut off, and my left hand. The stock BT3K switch cover is only 2.25 square inches in area and positioned where it is, can be a difficult target to hit the first time. There is a large switch on the market that measures something like 12” square, but my tool budget is a bit pinched. I came up with what amounts to an extension for the stock switch cover. I used a 6” wide by 10” long piece of thin rigid plastic. This produces a larger target of 60 square inches. This could be 1/8” plexiglas or thinner also. It doesn’t have to be very strong, just stiff enough to cause the switch to turn off when struck. It also can’t be very heavy or it will turn the saw off by it’s own weight. This cover extension is mounted on the existing cover with double sided carpet tape. This tape has fabric in it and is very strong. The extension could also be mounted with small screws and nuts if they were positioned to clear the switch mounting screws under the cover. The extension is mounted with 1” of it above the existing switch cover and centered on the cover. The bottom of the extension is then flush with bottom of the upper horizontal stand rail. This arrangement allows the entire cover to be raised to turn the saw on, or to remove the screws that hold the switch in the cabinet. It’s easy enough to slip your hand under the cover and turn the saw on without completely raising the cover. The larger surface area of this cover makes it easy to blindly reach down and shut off the saw with out looking. ...