Take a photo of your wiring ahead of time

Flip the Switch

It’s never a good day when a power tool gives up its magic blue smoke. When I was making a recent run of saw horses my jointer’s switch decided it had enough.

It’s a Delta X5 ‘Professional’ 6″ jointer with the 42″ beds. It’s the same one that had the large fence advancement knob break a while back requiring a modern make-do sort of fix.  For what was supposed to be a top of the line ‘professional’ machine for its size I’m disappointed with how many issues it has had related to the manufacturer cutting corners. I used to be a big fan of Delta but in recent years and especially with it being sold off from Pentair and later Black and Decker and the turmoil with it being owned by an overseas company that only seems to own some of the old Delta product lines I’ve been disappointed with the quality and longevity of these machines compared to the old iron 20th century versions of the same model tools.

Fried lead
Fried lead

I knew this switch was going to be trouble the minute I saw it in person as I have a Delta 36-980 Table saw of the same vintage and both purchased new in the late 2000s — that had the switch die — at least in that case of fused into the ‘On’ position so I was able to add a Rockler Router Table Switch  with a nice big crash pad on it and have a safe and reliable way to turn the machine on and off.

For either machine they want $50-65+ for a replacement switch assembly that likely would not last any longer and has an incredibly cheap feel to it. I didn’t want to hack the cable and try and hardwire in a similar Rockler switch on the jointer as the flimsy arm to hold the switch would require even more modifications.

Notice the now much shorter contact
Notice the now much shorter contact

When the switch decided to die it seems to have arced and burned up the contact inside the switch (As seen above and below)

Carbon on the contact (sawdust from leaving the broken part sitting around the shop for a while)
Carbon on the contact (sawdust from leaving the broken part sitting around the shop for a while)

Rather than throwing more good money after bad I figured with some research I could find another switch to insert into the housing that would have the same load ratings and have a much lower price and it took a while to find one I thought would work, but eventually I found the switch below:

Replacement Switch
Replacement Switch

At the time I bought it, they cost me about $10 each and I bought one for my jointer and one for the table saw. You can find this toggle switch here on Amazon.com

Take a photo of your wiring ahead of time
Take a photo of your wiring ahead of time

I opened up the housing, took a picture of the wiring via my phone so I could wire it back up correctly, unplugged the leads and compressed the snap fittings so I could pry the old switch out. The new switch popped in and the contacts fit fine. I neatened up the wires, gave the circuit a quick test and closed up the housing and put it back on the machine.

Delta X5 Jointer Switch Assembly
Delta X5 Jointer Switch Assembly

The replacement switch also has that built in child safety switch/pin that can be removed and seems to work fine with that large over button as seen above.

With a little bit of research I’m happy I was able to save a few bucks and get this machine back into service. Hopefully this new switch from another manufacturer will last longer.

Take care,

P.S. I know I have been slow about posting lately, but we just had our second baby and things have been very busy. I’ve been amassing more content from time out in the shop so for the next month or two likely posts will be coming out at a slower pace but I’m working to get through the back log.

4 thoughts on “Flip the Switch”

  1. Delta is in its death throes.
    I had the jointer and table saw and they both had numerous problems! Both gone!
    The table saw switch had a problem in that when it failed during a cut it and it wouldn’t turn off!!! Big problem!!! Had to pull the plug from the wall to shut it down!
    Called Delta and they said they were aware of that issue and send $65 and they would send me a replacement switch! What kind of thinking is that in a law suit happy world???
    Besides, where is he pride in making an industrial level tool that doesn’t last???

    1. Yep, that more or less the same experience I had. It’s sad to see a once great company die off like that. For a while there was some hope with that new Unisaw, but it seemed to be more marketing and hype and some overly complex and fragile mechanisms rather than actual improvement. If only they embraced the SawStop technology or similar things when they had the chance.

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