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Catastrophic Chop Saw Failure and Neglected Tool Repair Tips!

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Catastrophic Chop Saw Failure and Neglected Tool Repair Tips! In this video, I discover my 12" chop saw has suffered a catastrophic failure. I show you how I diagnose the problem, replaced the brushes and how to "seat" them if necessary. I also show you how I resurfaced the damaged part of the motor to save a little money and get some more life from the tool and i show you how to clean the commutator. I also discuss some tips and tricks on how to avoid this problem to begin with. CHECK OUT THE TOOLS & GEAR I USE 🔴 https://www.amazon.com/shop/brandonlund FOLLOW ME ON ⇨ Instagram: https://www.instagram.com/lunddiybuilds ⇨ Facebook: https://www.facebook.com/LundDIYBuilds
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Text Comments (42)
E Caff (7 months ago)
Brandon, you are a GENIUS. Just by chance I said what if my craftsman table saw needs new bushings and guess who's video I pulled up looking to repair my 25 year old Craftsman. Excellent video and process. Also, my saw is just for home shop because of the age and issues. Thanks to you, I may get another 25 years from this old Friend. Thank you for sharing. Bless you.
Brandon Lund (7 months ago)
I love this type of comment! There is no better feeling than knowing I helped someone maybe save a little money and keep a useful tool in service! Thank you! I'm glad I could help!
NVG (1 month ago)
Tell me this guy don’t look just like Michael Shannon ...nice content btw subbed
Brandon Lund (1 month ago)
Lol now if I just had his money lol. Thanks for the sub!
Mel Gross (2 months ago)
Honestly, this could have been avoided if the brushes were checked every five years, or so. If you use this on a regular basis, you have to assume the consumables, such as brushes, are going to wear out. That’s why they’re easy to change - and cheap. The brushes have to be formed to the curve of the commutator first. Eh, not the best way to do it, but I suppose better than nothing. The sandpaper isn’t following the shape of the commutator. The proper brushes are factory molded. You got lucky though. I’ve seen motors destroyed by bad brushes.
Brandon Lund (2 months ago)
I have no one to blame for this but myself, however the sandpaper tip is not anything I made up. It's actually quite common on large industrial motors. Profiling the brush to the commutator (even though they are profiled from the factory) is often standard procedure. Especially if the commutator has been turned down in size. Matching the brush to the profile of the commutator extends the life of the components. It's really not a bad idea to do in general.
Caroline Dordolo (4 months ago)
Can't believe i just found a video that shows what's going on inside the motor. I'm having a problem with scroll saw...mine has hardly been used, brushes are fine my dad says and i wanted to open the motor but i don't think i need to now...but i may try some new brushes anyways...just can't find them anywhere at the moment.. i have a problem with the wiring one blue wire from the switch is not getting any continuity but the red wire does. These go from the switch to the circuit board and into the motor. I unplugged them from the switch so i know the problem is in the board to the motor. It stops there because that's as far as i can go..i know nothing about circuit boards only to carefully open the scroll saw up and check all the wiring and put it back together. Your video is awesome and informative.Thank you
Caroline Dordolo (4 months ago)
Your absolutely correct!
Brandon Lund (4 months ago)
Thanks Caroline! I'm pretty proud of her. I think getting kids involved in a variety of different things builds confidence. She seems to like it, but if not she can always say she tried.
Caroline Dordolo (4 months ago)
+Brandon Lund i used to love going to the hardware store with my dad when i was a kid...my brother is the computer techy and i'm the hands on fixer upper person...lol...your daughter will follow in your footsteps when it comes to this sort of stuff whether she turns it into some sort of career or hobby ..good for her!
Caroline Dordolo (4 months ago)
Thanks Brandon...I have a few places I'm still checking around. I can't let this scroll saw go...like I said its still new to me. Not happy with Dremel as they don't make it anymore. I'm hoping to find someone like you who knows his stuff and can be straightforward. Thanks for your reply
Brandon Lund (4 months ago)
Thank you very much Caroline and I appreciate your support. One thing to consider once you find your bad part is look on ebay. You might be able to find the part you need or possibly a whole parts saw for less than what the part costs new.
Rol Tol (4 months ago)
Hi, im looking in to dewalt tools from usa and 120v, you took it a apart, but i could not see if there is any diagram for rewiring this tool for 240v ? cause i beleave dewalt is not making or designing seperate motors, its just the same motor but different wiring, i wonder if the tool have the wiring diagram for 240v ?
Brandon Lund (4 months ago)
There was not one under the cover and I do not have the original manual that came with the saw. I would not be surprised if the same motor was used for both voltages and then just wired differently.
24revealer (4 months ago)
You're lucky you didn't wreck the armature. I picked up a free Dewalt Circular saw the guy said there was a bad bearing. Got it home and the brushes were completely gone to the springs and had destroyed the commutator when one of them caught a bar. I was still able to use the gear assembly behind the blade for another saw (B&D Super Sawcat) that the bearing had been cracked right from the factory when new, so it wasn't a complete waste of my time. Whenever the brushes start sparking, they need to be looked at immediately to prevent other damage to the motor assembly. Brushes are inexpensive.
Brandon Lund (4 months ago)
Excellent advise! For me it seemed intimidating to mess around with them. Knowing what I know now, at the first sign of trouble I change them out. It's too easy not to.
martin hickey (6 months ago)
Great job bud
Brandon Lund (6 months ago)
Thank you very much!
A D (6 months ago)
I did exactly what you do to the commutator and bruches of a old drill. But when I try it the bruches was making to mush spark and the commutator was black in 2 seconds, so I take it appart and clean it again. I'am waiting at a solution right now... Any idea of the problem?
Brandon Lund (6 months ago)
From what your describing, it sounds like the brushes are not matching the contour of the communtator.
Andy O (7 months ago)
Thanks for the help man!
Brandon Lund (7 months ago)
Glad I could help brother!
KAREN BAKER (8 months ago)
Hi I have a performance mitre saw and I can't seem to get the motor out of its casing how can I do it
francisco barajas (10 months ago)
Brushes are made in China?
Brandon Lund (10 months ago)
I don't remember but its possible.
Kevin Dean (1 year ago)
Excellent repair video!! I am going to save $400 by replacing the brushes rather than replacing the whole bloody saw (DW708). A failure mode analysis website indicates that brush failure is 67% of the failure reasons.
Pro1er (1 year ago)
Kevin, if you use the bevel scale on your saw, check it for accuracy, mine was 2 degrees off! Dewalt uses rivets to hold the scale and it can move around.
Brandon Lund (1 year ago)
Thank you and I'm glad I was able to help! Now you can take that $400 you saved and spend half that on more tools....everyone wins! ;) Thanks for watching Kevin!
Jim Bendtsen (1 year ago)
Looks like you cut concrete covered forms with that saw.
Brandon Lund (1 year ago)
This saw has seen it all, ...including a fall out the back of a pickup.
rotoclip (1 year ago)
thank you, great tips.i use/abuse 4 inche angle grinders in my job .I've changed many brushes but never ever sanded down the comutators and they looked quite worn.i 'll plan on trying the sand paper trick in the future.what saw did you replace your retired saw with,upgraded perhaps to what make and model?
Brandon Lund (1 year ago)
rotoclip Same manufacturer. I have had excellent results with their chop saws, however, i personally have not had great luck in commercial enviroments with their other tools such as their reciprocating saws and drills. Based on my own experiences, I personally wouldn't own anything else other than a dewalt chop saw for production work. This saw has seen everyday production use, been used in the rain, fell out of a pickup. It's proven itself to me as far as I'm concerned. Here's a quick tip whenever you change your brushes or do an inspection, with the tool unplugged, stick a pencil that has the pink eraser through the brush holder and spin the arbor of the tool. This will clean your comutator. Your eraser will come out black. Give it a quick rub on your jeans to clean the eraser and do it again. Keep repeating until your eraser is no longer dirty. In my opinion, only sand the commutator as a last resort if it has deep scores. Thanks for watching and glad I could help brother!
James Smith (1 year ago)
now you tell me unplug the saw . just kidding they use to make tool for altenter and starter rebuilding for the comutator but i havent seen one since 1972 good job .thanks 4 doing the video its nice to some one fixing somthing insted of throwing it away
Brandon Lund (1 year ago)
Thanks James! I try and use a tool for as long as possible before I discard it.
Brandon Lund (1 year ago)
Thanks James for watching. We live in a disposable society. I'm old school. I try to fix something and keep it as long as possible.
Andrew Browner (1 year ago)
how often/long have you been using this saw? got 250+hours on a 12amp angle grinder and theyre hard hours, i check the brushes once or twice a year and they havent worn 1/3 yet still running original ones also nice trick with the armature in the drill chuck
George Wilson (1 year ago)
Andrew Brownero
Brandon Lund (1 year ago)
+Andrew Browner I've used this saw hard everyday for 5 years, which much of that was production work, until I retired it. I think if you keep an eye on your brushes and replace them when you see signs of wear, you will be all set. I waited WAY too long and never checked them.
PiDGE IAM (2 years ago)
A recent subscriber.....but I know now to also look out for a bad/crappy, blackened comutator. Thanks man I learned something 👍🏻 -Pidge
Brandon Lund (2 years ago)
+PiDGE IAM Thanks for the sub buddy and I'm glad I could help!
jimpecoy (2 years ago)
Great video!
Brandon Lund (2 years ago)
+jimpecoy Thanks buddy!

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