Homemade Table Saw 4 A Removable Insert and FineTuning

Materials Needed:

Plywood or MDF for the tabletop and base
Angle iron or aluminum extrusion for the fence and miter gauge slots
Steel or aluminum tubing for the miter gauge
Saw blade, arbor, and motor (repurposed from an existing circular saw or purchased separately)
Bearings or bushings for the arbor
Hardware (screws, bolts, nuts, washers)
T-track or T-slot extrusion for the miter gauge and fence
Inserts for the tabletop (made from plywood, MDF, or aluminum)
Adjustable feet or leveling pads for the base
Safety switch or paddle switch for powering the saw
Tools Needed:

Circular saw or table saw (for cutting plywood or MDF)
Drill and drill bits
Router and router bits (for cutting miter gauge slots and T-tracks)
Welder or metal adhesive (for assembling the fence and miter gauge)
Screwdriver and wrenches
Sandpaper and files (for smoothing edges and adjusting fit)
Step-by-Step Guide:

Design the Table Saw:

Sketch out your design for the table saw, including the dimensions of the tabletop, base, fence, miter gauge, and removable inserts. Consider ergonomic factors and safety features in your design.
Prepare the Tabletop and Base:

Cut the plywood or MDF to size for the tabletop and base of the table saw. Ensure that the tabletop is flat and smooth, as this will affect the accuracy of your cuts.
Install the Motor and Arbor:

Mount the circular saw motor onto the underside of the tabletop, aligning it with the center of the blade opening. Secure the motor in place using screws or bolts. Attach the saw blade to the motor's arbor, making sure it is centered and aligned properly.
Fabricate the Fence and Miter Gauge:

Construct the fence and miter gauge using angle iron, aluminum extrusion, or other suitable materials. Weld or glue the pieces together to create sturdy assemblies. Install T-tracks or T-slot extrusions onto the fence and tabletop to accommodate accessories and attachments.
Add the Removable Inserts:

Cut inserts from plywood, MDF, or aluminum to fit into the blade opening on the tabletop. These inserts should be removable to accommodate different blade sizes and angles. Use screws or bolts to secure the inserts in place, allowing for easy removal and replacement.
Fine-Tune the Alignment:

Adjust the position of the motor and arbor to ensure that the blade is parallel to the miter gauge slots and fence. Use shims or spacers as needed to achieve precise alignment. Check the alignment using a straightedge or precision measuring tools.
Install the Safety Switch:

Mount a safety switch or paddle switch onto the table saw base, within easy reach of the operator. This switch should be used to power the saw on and off, providing an additional safety feature during operation.
Test and Adjust:

Once the table saw is fully assembled, test its functionality by making test cuts in scrap wood. Check the accuracy of the cuts and the stability of the fence and miter gauge. Make any necessary adjustments to fine-tune the saw for optimal performance.
Finish and Customize:

Sand and finish the tabletop and base to protect the wood and enhance its appearance. Add any additional features or accessories, such as dust collection ports or auxiliary fences, to customize the table saw to suit your needs.
Safety Precautions:

Always wear appropriate safety gear, including safety glasses and hearing protection, when operating power tools. Familiarize yourself with the operation of the table saw and follow all safety guidelines provided by the manufacturer.
By following these steps, you can create a homemade table saw with a removable insert and fine-tuning capabilities that will serve as a versatile and reliable tool for your woodworking projects.