Shopmade Thigh Switch

Yesterday I finally got to build a safety/hands-free switch for my Woodfast lathe.  I used a footswitch on my mini for a long time, but was unable to find the same type for the DC motor on this lathe.  I find the thigh switch is far superior and a much needed safety feature as well as an ideal aid when I need both hands free – such as when I am parting off a spindle project.  The switch is made from scrap wood with a few additional hardware purchases.  The hardware includes the continuous hinge, rare earth magnets, 1/4” x 20 tpi tap bolts (with washers and nuts) and #9 springs.  The springs provide some resistance when pushing against the switch and ensure it returns to its starting position after doing its job.  The springs are mounted behind the large “flipper/paddle” board and are secured/aligned using the tap bolts.  The paddle that is making contact with the off (red) button is cut for easy access when using a hand and for seeing and reaching the speed control knob.  There is no particular reason for the shape of the “flipper” board other than there was a split at one end that I had to work around to make use of its full length.

Thigh_switch_Woodfast

The video is a short demonstration showing how the switch works from any position along the bed.  Enjoy!

 

(12/3/2017) I rebuilt the switch with plywood and epoxied magnets.  I had originally used hot glue on the magnets while I tested the design–they lasted four or so years, but eventually broke out of their holes when the glue became brittle.  I also adjusted the sensitivity of the switch by closing the gap between the off button and the switch paddle.

Best regards,

Matt

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