owners manual MODEL 1680, VARIABLE SPEED 16 SCROLL SAW
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Voltage rating Amperage rating No load speed Throat Blade Blade stroke Cutting capacity
120 V 50 - 60Hz 1.4 A n0 500-1,600/min Plain and pin-end 3/at 0; 1 at 45
assembly operation safety instructions
P.O. Box 1468 Racine, Wisconsin

1-800-437-3635

http://www.dremel.com
Form No. 2610914195 7/01 Printed in Taiwan

General Safety Rules

! WARNING
READ ALL INSTRUCTIONS Failure to follow the safety rules listed below and other basic safety precautions may result in serious personal injury.

Work Area

KEEP CHILDREN AWAY Do not let visitors contact tool or extension cord. All visitors should be kept away from work area. KEEP WORK AREAS CLEAN Cluttered areas and benches invite accidents. MAKE WORKSHOP CHILD-PROOF With padlocks, master switches. AVOID DANGEROUS ENVIRONMENTS Dont use power tools in damp or wet locations. Keep work area well lit. Do not expose power tools to rain. Do not use the tool in the presence of flammable liquids or gases.
DISCONNECT TOOLS FROM POWER SOURCE When not in use, before servicing, when changing blades, bits, cutters, etc. KEEP GUARDS IN PLACE In working order, and in proper adjustment and alignment.
REMOVE ADJUSTING KEYS AND WRENCHES Form the habit of checking to see that keys and adjusting wrenches are removed from tool before turning it on. AVOID ACCIDENTAL STARTING Make sure the switch is in the OFF position before plugging in tool. GROUND ALL TOOLS This tool is equipped with an approved 3-conductor cord and a 3 prong grounding type plug to fit the proper grounding type receptacle. The green conductor in the cord is the grounding wire. Never connect the green wire to a live terminal. NEVER STAND ON TOOL OR ITS STAND Serious injury could occur if the tool is tipped or if the cutting tool is accidentally contacted. Do not store materials on or near the tool such that it is necessary to stand on the tool or its stand to reach them. CHECK DAMAGED PARTS Before further use of the tool, a guard or other part that is damaged should be carefully checked to ensure that it will operate properly and perform its intended function. Check for alignment of moving parts, mounting, and any other conditions that may affect its operation. A guard or other part that is damaged should be properly replaced. All repairs, electrical or mechanical, should be attempted only by trained repairmen. Contact the nearest Dremel Service Center, Authorized Dremel Service Station or other competent repair service. ! WARNING ! WARNING Use only Dremel replacement parts; any others may create a hazard.

Personal Safety

KNOW YOUR POWER TOOL Read and understand the owners manual and labels affixed to the tool. Learn its application and limitations as well as the specific potential hazards peculiar to this tool. DONT OVERREACH Keep proper footing and balance at all times. STAY ALERT Watch what you are doing. Use common sense. Do not operate tool when you are tired. Do not operate while under medication or while using alcohol or other drugs. DRESS PROPERLY Do not wear loose clothing or jewelry. They can be caught in moving parts. Rubber gloves and non-skid footwear are recommended when working outdoors. Wear protective hair covering to contain long hair. USE SAFETY GLASSES Also face or dust mask if cutting operation is dusty, and ear plugs during extended periods of operation. Everyday eyeglasses have only impact resistant lenses, they are NOT safety glasses. GUARD AGAINST ELECTRIC SHOCK Prevent body contact with grounded surfaces. For example: pipes, radiators, ranges, refrigerator enclosures.

10. PROTECTION: Eyes, hands, face, ears and body. ! WARNING TO AVOID BEING PULLED INTO THE BLADE

DO NOT WEAR:

Loose Fitting Gloves Necktie Loose Clothing Jewelry
DO: TIE BACK LONG HAIR ROLL LONG SLEEVES ABOVE ELBOWS a. If any part of your saw is missing, malfunctioning, has been damaged or broken. such as the motor switch, or other operating control, a safety device or the power cord.cease operating immediately until the particular part is properly repaired or replaced. b. Do not cut piece too small to hold by hand. HINT: When making a very small cut out, always secure the workpiece to a scrap piece of plywood with doublefaced tape. This way, the work is supported and your fingers are away from the blade. c. Never turn your Scroll Saw on before clearing the table of all objects (tools, scraps of wood, etc.) except for the workpiece and related feed or support devices for the operation planned.
d. Avoid awkward hand positions where a sudden slip could cause a hand to move into the blade. ALWAYS adjust the drop foot to just clear the workpiece to protect the operator, keep blade breakage to a minimum and provide maximum support for blade. Always adjust blade tension correctly. The Scroll Saw should cut on the down stroke. Always make sure blade teeth are oriented downward toward table. When cutting a large piece of material, make sure it is supported at table height. Hold the work firmly against the table. Do not feed the material too fast while cutting. Only feed the material fast enough so that the blade will cut. Keep fingers away from the blade. Use caution when cutting off material which is irregular in cross section it could pinch the blade before the cut is completed. A piece of molding, for example, must lay flat on the table and not be permitted to rock while being cut. Use caution when cutting off round material such as dowel rods or tubing. They have a tendency to roll while being cut, causing the blade to bite. e. Never leave the Scroll Saw running unattended. Turn the saw OFF, make sure the saw has come to a complete stop, and then remove plug from power supply before leaving the work area. f. Do not perform layout, assembly or setup work on the table while the cutting tool is operating. g. Turn saw off and remove plug from power supply outlet before installing or removing an accessory attachment. h. Access Door must be closed before operation.

Wear Eye Protection

i. Quick Release Tension Lever should be in down position before operating. 11. THINK SAFETY SAFETY IS A COMBINATION OF OPERATOR COMMON SENSE AND ALERTNESS AT ALL TIMES WHEN THE SCROLL SAW IS BEING USED. Do not allow familiarity (gained from frequent use of your Scroll Saw) to become commonplace. Always remember that a careless fraction of a second is sufficient to inflict severe injury. ! WARNING

WARNING

The operation of any power tool can result in foreign objects being thrown into the eyes, which can result in severe eye damage. Always wear safety goggles that comply with ANSI Z87.1 before commencing power tool operation.

Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are: ! WARNING Lead from lead-based paints, Crystalline silica from bricks and cement and other masonry products, and Arsenic and chromium from chemically treated lumber. Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.
NOTE AND FOLLOW THE SAFETY WARNINGS AND INSTRUCTIONS THAT APPEAR ON THE PANEL ON SCROLL SAW HOUSING:
Motor Specifications and Electrical Requirements

Motor Specifications

In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This Scroll Saw is designed to use a Variable Speed RPM motor. It is wired for operation on 110-120 volts, 60 Hz. alternating current. Before connecting the motor cord to power source, make certain the switch is in the OFF position and be sure the electric current is of the same characteristics as stamped on the nameplate. prong in the attachment plug at the other end. This plug requires a mating 3-conductor grounded type outlet as shown. It must be grounded in accordance with all local codes and ordinances. If the outlet you are planning to use for this power tool is of the two-prong type, DO NOT REMOVE OR ALTER THE GROUNDING PRONG IN ANY MANNER. Have a qualified electrician replace the TWO-prong outlet with a properly grounded THREE prong outlet. Improper connection of the equipment-grounding conductor can result in a risk of electric shock. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal. Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the tool is properly grounded. The temporary adapter should be used only until a properly grounded outlet can be installed by a qualified electrician. The green grounding lug extending from the adapter must be connected to a permanent ground such as a properly grounded outlet box. ! WARNING

GROUNDING LUG

Connection To A Power Source
This machine must be grounded while in use to protect the operator from electric shock. Plug power cord into a 110-120V properly grounded type outlet protected by a 15-amp dual element time delay fuse or circuit breaker. Not all outlets are properly grounded. If you are not sure that your outlet, as pictured below, is properly grounded; have it checked by a qualified electrician. To avoid electric shock, do not touch the metal prongs on the plug when installing or removing the plug to or from the outlet. !

DANGER

Failure to properly ground this power tool can cause electrocution or serious shock, particularly when used near metal plumbing or other metal objects. If shocked, your reaction could cause your hands to hit the tool. !

3-PRONG PLUG

MAKE SURE THIS IS CONNECTED TO A KNOWN GROUND
If power cord is worn, cut or damaged in any way, have it replaced immediately to avoid shock or fire hazard. ! WARNING Your unit is for use on 120 volts; it has a plug that looks like the one below.

ADAPTER

2-PRONG RECEPTACLE
NOTE: The adapter illustrated is for use only if you already have a properly grounded 2-prong receptacle. Adapter is not allowed in Canada by the Canadian Electrical Code. Always use proper extension cord. The use of any extension cord will cause some loss of power. To keep this to a minimum and to prevent overheating and motor burn-out, use the table below to determine the minimum wire size (A.W.G.) extension cord. Use only 3-wire extension cords which have 3-prong grounding type plugs and 3pole receptacles which accept the tools plug. Make sure your extension cord is in good condition. Extension Cord Length 0-25 Feet 26-50 Feet 51-100 Feet Wire Size A.W.G. 16

GROUNDING PRONG

ALWAYS USE A GROUNDED OUTLET
This power tool is equipped with a 3-conductor cord and grounding type plug, approved by Underwriters Laboratories and the Canadian Standards Association. The ground conductor has a green jacket with or without yellow stripes and is attached to the tool housing at one end and to the ground

Table of Contents

General Safety Rules..2 Additional Safety Rules..3-4 Motor Specifications and Electrical Requirements...5 Connection to a Power Source..5 Unpacking and Checking Contents..7 Table of Loose Parts...7 Glossary of Terms..8 Getting to Know Your Scroll Saw..8-9 Operating Adjustments..10 Setting the Table for Horizontal or Bevel Cutting.10 Aligning the Degree Scale Pointer..10 Basic Scroll Saw Operations..11-14 Removing and Installing Pin-End Blades.12 Removing and Installing Plain-End Blades..12 Adjusting the Lamp...13 Replacing the Bulb...13 On/Off Switch...13 Variable Speed Switch..13 Reset Button...13 Making Interior Scroll Cuts Pin-End Blades and Plain-End Blades..14 Mounting the Scroll Saw..15-16 Mounting the Scroll Saw to a Bench..15 Mounting the Scroll Saw to Plywood..16 Attaching Scroll Saw to Leg Set..16 Maintaining Your Scroll Saw..17 Lubrication...17 Recommended Accessories..18 Trouble Shooting..19 Dremel Limited Warranty...22 Service Parts List..61-64
Unpacking and Checking Contents
To avoid injury from unexpected starting or electrical shock, always remove plug from power source when tool is not in use. ! WARNING Model 1680 Motorized Scroll Saw is shipped complete in one carton. 1. Unpacking and Checking Contents. Separate all loose parts from packing materials and check each item with the Table of Loose Parts to make sure all items are accounted for before discarding any packing material. If any parts are missing, do not attempt to ! WARNING operate Scroll Saw, plug in the power cord or turn the switch on until the missing parts are obtained and are installed correctly. Table of Loose Parts Item A B C Description Qty. 16 Scroll Saw...1 Owners Manual...1 Loose Parts Bag (containing).1 Allen Wrench (3 mm)..1 Allen Wrench (5 mm)..1 Blades...11
NOTE: Hardware to mount this Scroll Saw to a bench or leg set is NOT supplied. See mounting instructions on Page 15-16 for recommended hardware size. To remove protective coating from the table surface, moisten a soft cloth with kerosene and wipe off coating. Do not use acetone, gasoline or lacquer thinner for this purpose. After removing protective coating, If you wish, you may apply a coat of paste wax to the table to allow the workpiece to slide easily across the table surface and deter rust. Wipe the table thoroughly with a clean dry cloth.

Tools Needed

COMBINATION SQUARE MUST BE TRUE
Check its accuracy as illustrated below.
STRAIGHT EDGE OF BOARD 3/4 THICKTHIS EDGE MUST BE PERFECTLY STRAIGHT

PHILLIPS SCREWDRIVER

DRAW LIGHT LINE ON BOARD ALONG THIS EDGE
WRENCHES 7/16 in. COMBINATION SQUARE SHOULD BE NO GAP OR OVERLAP WHEN SQUARE IS FLIPPED OVER IN DOTTED POSITION

Glossary of Terms

KERF The slot cut by the blade. LEADING EDGE The edge of the workpiece which is pushed into the blade first. SAWBLADE PATH The area of the workpiece directly in line with and moving toward the sawblade edge. BLADE TOOTH SET The distance that the edge of the sawblade tooth is bent (onset) outward from the side of the blade. TRAILING EDGE The workpiece edge last cut by the sawblade. WORKPIECE The item on which the cutting operation is being performed.

Getting to Know Your Scroll Saw
This versatile Scroll Saw is great for making toys, puzzles, games, fretwork, and jewelry. Because of its cutting capacity, it is a handy do-it-yourself tool. It cuts wood up to 2 inches thick as well as plastics and non-ferrous metals. 1. BLADE & WRENCH STORAGE CASE Your Scroll Saw is equipped with a blade storage area located on the easy access door of the saw. The blade storage area conveniently stores your allen wrenches, and both Pin and Plain end blades. 2. SAWDUST BLOWER Keeps workpiece clean for more accurate scroll cuts. For best results, always direct air flow from blower tube at blade and workpiece. To adjust, simply bend to desired position. 3. VACUUM HOOK-UP Your Scroll Saw is equipped with a vacuum hook-up. This feature will allow you to attach any 1-1/4" vacuum hose into the hole provided for convenient sawdust removal. 4. DROP FOOT The foot should always be lowered until it just rests on top of the workpiece to prevent workpiece from lifting, but not so much that the workpiece drags. 5. DROP FOOT LOCK KNOB Allows you to raise or lower the foot and lock it at desired heights. 6. QUICK RELEASE TENSION LEVER Allows you to quickly loosen, or tighten the blade to its original tension with lever action. 7. TABLE LOCK KNOB Allows you to tilt the table and lock it at desired angle up to 45 degrees to the right or left. 8. DEGREE SCALE Shows the degree the table is tilted. 9. VARIABLE SPEED DIAL Your Scroll Saw is equipped with a variable speed dial for greater versatility. 10. POWER ON/OFF SWITCH Has holes provided by the switch for a lock (not included). THIS FEATURE IS INTENDED TO PREVENT UNAUTHOURIZED AND POSSIBLY HAZARDOUS USE BY CHILDREN AND OTHERS. To turn saw on, push power switch to the on position; to turn saw off, push power switch to the off position. 11. LIGHT SWITCH To turn light on, push light switch to the on position; to turn light off, push light switch to the off position. 12. TABLE Provide working surface to support workpiece. 12.a TABLE INSERT Should always be in place and flush with table during cutting operation. 13. LIGHT Illuminates the workpiece. 14. EASY ACCESS DOOR Allows easy access to lower blade holder when changing blades. 15. CIRCUIT BREAKER Protects motor from from overheating and damage. 16. TABLE TILT DETENTS Automatically stops the table to the right or left at 0, 15, 30, and 45 degree increments. 17. ALLEN WRENCHES Convenient wrenches, assists in making blade changes and adjustments if desired.

FIG. 1

6 QUICK RELEASE TENSION LEVER 9 VARIABLE SPEED DIAL 10 POWER ON/OFF SWITCH

5 DROP FOOT LOCK KNOB

11 LIGHT SWITCH

13 LIGHT

4 DROP FOOT 12a TABLE INSERT 2 SAWDUST BLOWER 12 TABLE

7 TABLE LOCK KNOB

15 CIRCUIT BREAKER 1 BLADE & WRENCH STORAGE CASE 14 EASY ACCESS DOOR 8 DEGREE SCALE 16 TABLE TILT DETENTS

3 VACUUM HOOK-UP

VACUUM HOOK-UP

FIG. 2

FIG. 3

Operating Adjustments

Setting the Table for Horizontal or Bevel Cutting
1. Loosen the table lock knob, and the saw table can be tilted to the right or left and locked at any angle from 0 degree horizontal cutting position up to 45 degrees for bevel cutting (Fig. 4). Your tool also features table tilt dentents which automaticlly stops the table to the right or left every 15 degrees. 2. A degree scale is also provided under the work table as a convenient reference for setting the approximate table angle for bevel cutting. When greater precision is required, make practice cuts and adjust the table as necessary for your requirements. Adjusting the hold down clamp The hold down clamp should always rest just above the workpiece to help prevent the workpiece from lifting from the table. 1. Hold the drop foot, loosen the drop foot lock knob and lower by hand until it just rests above the workpiece surface, and securely tighten the drop foot lock knob. 2. When cutting with the table angled, adjust drop foot so its parallel to the table. To adjust, loosen screw with the allen wrench provided, turn foot to correct angle, tighten screw. Always make sure the blade does not contact either side of the drop foot, or the table opening. NOTE: When cutting at extreme angles, the drop foot should be lifted off the workpiece, as it will impede cutting. Hold the workpiece against the table. The drop foot may be disassembled when thick materials are cut at extreme angles. FIG. 4

DROP FOOT LOCK KNOB

DROP FOOT

MOUNTING SCREW TABLE

TABLE LOCK KNOB

DEGREE SCALE

Aligning the Degree Scale Pointer
The table is factory set to 0. If further adjustments are necessary, please follow the instructions below: 1. Loosen the table lock knob and move the table until it is 90 degree to the blade. 2. With the wrench provided remove the drop foot assembly, mounting screw, and washer, and move it out of the way. Place a small square on the table next to the blade as shown in (Fig. 5) to check if the table is 90 to the blade. If no adjustment is required, replace the drop foot assembly, washer and screw. If adjustment is necessary. Loosen, but dont remove the two screws holding the pointer. With the steel ball centered in the 0 detent, slide the pointer left or right until the blade is parrallel to the square. 4. Tighten the table lock knob, both screws, and replace drop foot, washers and screw. Remember, the degree scale is a convenient guide but should not be relied upon for precision. Make practice cuts in scrap wood to determine if your angle setting is correct.

FIG. 5

MOUNTING SCREW BLADE SQUARE
POINTER POINTER ADJUSTMENT SCREW

STEEL BALL

Basic Scroll Saw Operations
Follow these instructions for operating your Scroll Saw to get the best results and to minimize the likelihood of personal injury. ! WARNING AND 5. 1. Protection: Eyes, Hands, Face, Ears and Body ! WARNING TO AVOID BEING PULLED INTO THE BLADE ALWAYS OBSERVE THE SAFETY PRECAUTIONS HERE AND ON PAGES 2, 3, 4, Best results are achieved when cutting wood less than one inch thick. When cutting wood thicker than one inch the user must feed the wood very slowly into the blade, increase blade tension and take extra care not to bend or twist the blade while cutting in order to maximize blade life. Teeth on Scroll Saw blades wear out and as such must be replaced frequently for best cutting results. Scroll Saw blades generally stay sharp for 1/2 hour to 2 hours of cutting. To get accurate cuts be prepared to compensate for the blades tendency to follow the wood grain as you are cutting. When choosing a blade to use with your Scroll Saw consider the following carefully: Choose a blade that allows at least three (3) teeth to be in contact with the workpiece at all times. DO: TIE BACK LONG HAIR ROLL LONG SLEEVES ABOVE ELBOWS Very fine, narrow blades should be used to scroll cut in thin wood (1/4 inch thick or less). To cut thicker wood, use wider blades with fewer teeth per inch. Most blade packages state the size or thickness of wood which that blade is intended to cut, and the radius (size of curve) which can be cut with that blade. Wider blades cant cut curves as tight or small as thinner blades. This saw uses 5 inch long, Pin or Plain-End type blades only (See Accessories on page 18). Blades wear faster when (1) cutting plywood, which is very abrasive, (2) when sawing wood which is thicker than the 3/4 inch blade stroke, and (3) when sawing hardwood, or when side pressure is placed on the blade.
The saw does not cut wood by itself. You allow the saw to cut wood by guiding the wood into the blade as it moves. The blade teeth cut ONLY on the down stroke. The drop foot should always be lowered until it just rests on top of the workpiece. You must feed the wood into the blade slowly because the teeth of the blade are very small and they can only remove wood when they are on the down stroke. The blade will flex backwards when applying feed pressure. Too much feed pressure will cause blade breakage. There is a learning curve for each person who wants to use this saw. During that period of time it is expected that some blades will break until you learn how to use the saw and receive the greatest benefit from the blades.

SLIGHT PRESSURE HERE CLAMP KNOB

FIG. 6

LOOSEN UPPER BLADE HOLDER BLADE TABLE TILTED FOR PICTURE CLARITY QUICK RELEASE TENSION LEVER

TIGHTEN

FIG. 7

LOWER BLADE HOLDER

QUICK RELEASE TENSION LEVER

FIG. 8

CLAMP KNOB

Adjusting the Lamp

1. Position the lamp as needed to illiminate the workpiece. 2. Loosen lock knob, slide lamp to desired position and tighten lock knob (Fig. 9). Note: Lamp shade angle is fixed and cannot be adjusted.
OUTER SHADE COVER LOCK KNOB

Replacing the Bulb

1. Use only a (25 watt maximum), candelabra base bulb. Turn the light switch off and unplug the saw. 2. Remove the shade screw and the outer shade cover. 3. Slide the inner shade off the bulb socket. 4. Replace bulb and reassemble the shades (Fig. 9). Note: Additional bulbs are available through Customer Service.

INNER SHADE SHADE SCREW

FIG. 9

ON/OFF Switch

1. To turn power ON or OFF push the power switch (Fig. 10).

Variable Speed Switch

1.Your saw is equipped with a variable speed dial. The blade stroke rate may be adjusted by simply rotating the dial (Fig. 10). To increase speed, rotate dial clockwise. To reduce speed, rotate dial counterclockwise. FIG. 10

VARIABLE SPEED DIAL

Reset Button
Your saw features a reset button that protects the motor from overheating and damage (Fig. 11). 1. If the switch pops, turn the power ON/Off switch to the off position. 2. Unplug the cord from the power source and allow the saw to cool down. 3. Return reset button to its original position.

POWER ON/OFF SWITCH

OFF OFF

LIGHT SWITCH

FIG. 11

RESET BUTTON

3 A M P
Making Interior Scroll Cuts
(Pin-End Blades and Plain-End Blades)
TO AVOID ACCIDENTAL STARTING, ALWAYS TURN SWITCH OFF AND REMOVE PLUG FROM POWER SOURCE BEFORE REMOVING OR REPLACING THE BLADE. ! WARNING A main benefit of this saw is the ability to perform intricate interior cuts quickly and easily. This is best accomplished using the Quick Release Tension Lever. Simply follow these steps (Fig. 12): 1. Drill appropriate sized pilot hole in work piece. 2. Release Quick Release Tension Lever. 3 Remove the blade from the upper blade holder as explained on page 12 Removing and Installing (Pin-End) or (Plain-End) blades. 4. Thread blade through pilot hole from underneath the workpiece. If needed, remove the table insert. This will allow the blade to fall forward for more clearance between the workpiece and the upper arm housing. Reinstall the blade in the upper blade holder. 5. Retension blade by pulling tension lever down. 6. Lower drop foot until it just rests on top of the workpiece and youre ready to begin cutting. 7. When finished making the interior scroll cuts simply remove the blade from the blade holders, as described on page 12 Removing and Installing (Pin-End) or (Plain-End) blades, and remove the board from the table. FIG. 12

Mounting the Scroll Saw

Mounting the Scroll Saw to a Bench
1. The Scroll Saw should be fastened securely to a firm supporting surface such as a stand or workbench, using the four mounting holes. Note: When mounting this saw to a workbench, a solid bench is preferable to a plywood bench where noise and vibration will be more noticeable. We recommend to reduce noise and vibration, that a soft foam pad be placed between your Scroll Saw and workbench. (Not Supplied)

16 3/1/4 5/16 Dia.

FIG. 13
Quantity Description 1 Soft foam pad, such as carpet padding, 24x12x1/2 2. When mounting the Scroll Saw to a workbench, holes should be drilled through the foam pad or carpet and mounting surface of the workbench using the dimensions illustrated in Figure 13. Each of the four mounting holes should be bolted securely using no less than 1/4 hex bolts, flat washers, lock washers, and nuts. We recommend: Quantity Description 4 Hex Head Bolts, 1/4-20 x 1/4-20 x Length Required 4 Flat Washers, 9/32 I.D. 4 Lockwasher, 9/32 I.D. 8 Hex Nuts, 1/4-20 (Hardware not supplied) A. Locate and mark where the Scroll Saw is to be mounted. B. Drill the four 5/16 holes through the workbench. C. Place the Scroll Saw on the workbench aligning holes in the base with the holes drilled in the workbench. Insert all four (4) screws and tighten. Note: Do NOT overtighten mounting bolts - leave some cushion in the foam pad for absorbing noise and vibration. ATTENTION: When inserting the front right hex head bolt, it will be necessary to insert the hex head bolt from the bottom side of the workbench, and secure with hex nut from the top side of Scroll Saw Base. Example of mounting this Scroll Saw to workbench (Fig. 14).

HEX HEAD BOLT

1/2 Foam Pad or Carpet (optional)

FIG. 14

SCROLL SAW BASE

WORKBENCH

LOCKWASHER JAM NUT

FLATWASHER HEX NUT

FIG. 15
Mounting the Scroll Saw to Plywood
An alternative method of securing your Scroll Saw is to fasten the Scroll Saw base to a mounting board 18 x 24. Any good grade of plywood with a 3/4 minimum thickness is recommended. Follow the instructions for Mounting the Scroll Saw to a Bench, substituting the 18 x 24 board for the workbench and using 1/4-20 Flat Head Screws for the Hex Screws (Fig.15). Note: For proper stability, holes must be counter sunk so screw heads are flush with the bottom surface of the supporting board. Securely clamp board to workbench using two or more C Clamps. FIG. 16

Carbon Brushes

The brushes and commutator in your tool have been engineered for many hours of dependable service. To maintain peak efficiency of the motor, we recommend every two to six months the brushes be examined. Only genuine Dremel replacement brushes specially designed for your tool should be used. The brushes should be inspected frequently when tools are used continuously. If your tool runs sporadically, loses

FIG. 18

BRUSH CAP

FIG. 17

BRUSH SPRING

Recommended Accessories

Use only Dremel accessories. Follow instructions that accompany accessories. Use of improper accessories may cause hazards. LEG SET Cat. No. 16500 Scroll Saw Stand

Saw Blades

Dremel offers both Plain and Pin-End 5 inch blades. PIN-END Pin-End blades permit relatively tight radius cutting in hard and soft wood. Cat. No. 16413 Suggested Usage For cutting wood 3/8 to 2 thick For cutting wood 3/16 to 1 thick For cutting wood thinner than 1/4 thick Width Thick TPI.110 x.018 x 10.110 x.018 x 15.070 x.010 x 18.5 Speed Any Any Any
PLAIN-END The Pin-End blades, while somewhat easier to put in and take out of the machine, do not always produce the same controlled cutting action provided with the Plain-End blade. These narrow Plain-End blades allow the user to cut more detailed, intricate patterns and smaller inside cuts. Cat.No. 16448 Suggested Usage For cutting hard and soft woods 1/4 to 2 thick For close radius cutting in materials 1/8 or thicker For very tight radius work in thin materials, up to 1/8 Width Thick.062 x.020.038 x.016.029 x.012.022 x.010.045 x.017 TPI 9.5 12.28 11.5 Speed High High High High High

x x x x x

SPIRAL Saws in all directions without turning the workpiece. Cat. No. Suggested Usage For wood, plastic and abrasive materials Kerf TPI.028 -.030 x 46.034 -.036 x 41 Speed Any
METAL PIERCING For cutting precious and non-ferrous metals; these must be used at very slow speeds. They perform well on machines that have variable speed capability and should be lubricated with beeswax, or a light machine oil. Cat. No. Suggested Usage Kerf TPI Speed 16483 Metals and other hardwood materials.033 x.016 x 36 Low REVERSE TOOTH Provides a smooth, splinter free finish. Eliminates the need for excessive finish sanding, and leaves a clean sharp edge on both the top and bottom of your workpiece. Cat. No. 16433 Suggested Usage For cutting hard or soft woods up to 1/8 thick. For cutting hard or soft woods 1/8 or thicker For cutting hard or soft woods 3/8 to 2 thick Kerf TPI.029 x.012 x 20.038 x.016 x 12.5.047 x.017 x 11.5 Speed Any Any Any
PERMA-GRIT TUNGSTEN CARBIDE Shapes and cuts ceramic tiles cleanly and accurately. Cuts intricate patterns easily in any direction. Also use for thin wood. Not for use on ceramic floor tile. Cat. No. Suggested Usage For very tight radius work in cearmic tile or thin wood. For close radius cutting in ceramic tile or thin wood. Kerf.031 x.033.046 x.048 Grit Speed Medium Medium

Troubleshooting

! WARNING Turn switch OFF and always remove plug from the power source before troubleshooting. TROUBLE Breaking blades. PROBLEM 1. Wrong tension. 2. Over working blade. 3. Wrong blade application. REMEDY 1. Adjust blade tension, see REMOVING AND INSTALLING BLADES, Page 12 (Pin End) or (Plain End). 2. Reduce feed rate, see BASIC SCROLL SAW OPERATION, Page 11. 3. Use narrow blades for cutting thin wood, wide blades for thicker wood. 4. Avoid side pressure on blade. 5. Blade should have minimum 3 teeth in contact with workpiece. Replace defective parts before using saw again. 2. & 3. Consult Dremel Service. Any attempt to repair this motor may create a HAZARD unless repair is done by a qualified service technician. 4. Replace both brushes. 1. See MOUNTING YOUR SCROLL SAW, Pages 15 & 16. 2. The heavier your work bench is, the less vibration will occur. A plywood workbench will not be as good a work surface as the same size solid lumber. Use common sense in choosing a mounting surface. 3. Tighten table lock knob. 1.
4. Twisting blade in wood. 5. Incorrect teeth per inch.

Motor will not run.

1. Defective cord or plug. 2. Defective motor. 3. Defective wire connections. 4. Brushes worn.
Vibration NOTE: There will always be some vibration present when the saw is running because of motor operation.
1. Improper mounting of saw. 2. Unsuitable mounting surface.
3. Loose table or table resting against motor.

Dremel Limited Warranty

Your Dremel product is warranted against defective material or workmanship for a period of two years from date of purchase. In the event of a failure of a product to conform to this written warranty, please take the following action: 1. DO NOT return your product to the place of purchase. 2. Carefully package the product by itself, with no other items, and return it, freight prepaid, along with: A. A copy of your dated proof of purchase (please keep a copy for yourself). B. A written statement about the nature of the problem. C. Your name, address and phone number to: UNITED STATES Dremel Service Center 4915 Twenty-First Street Racine, Wisconsin 53406 CANADA Giles Tool Agency 6520 Lawrence Av. East Scarborough, Ont. Canada M1C 4A7 Dremel Service Center 4631 E. Sunny Dune Palm Springs, CA 92264 OUTSIDE CONTINENTAL UNITED STATES See your local distributor or write to Dremel, 4915 Twenty-First St. Racine, Wisconsin 53406

6 58/58

MODEL 1680 TYPE 2 SCROLL SAW MODLE 1680, TYPE 2 SCIE CHANTOURNER SIERRA CALADORA TIPO 2 MODELO 1680

22 650/13 28

650/14
ORDER BY PART NUMBER, NOT CODE NUMBER
CODE NO. DESCRIPTION Light Assembly (1) Light Bulb 25 W (1) Support Rod (1) Blade Guard (1) Linking Bracket (1) Blade Holder Assembly (2) Washer (4) Washer (1) Bearing Seat Assembly (1) Washer (1) Washer (1) Washer (4) Washer (1) Washer (4) Washer (1) Washer (1) Washer (1) Washer (1) Bolt (4) Bolt (1) Bolt (2) Bolt (1) Bolt (1) Knob (1) Knob (1) Set Screw (1) Bolt w/ Washer( 3) Bolt w/ Washer (1) Bolt w/ Washer (3) Screw (1) PVC Hose (1) Blower Housing (1)
PART NO. 2615303004 2615303005
DESCRIPTION Rocker Switch (2) Cord 120V (1) Strain Relief (2) Cord Clamp (4) Nameplate (1) Dust Boot (2) Screw (6) Warning Label Plate (1) Foot (4) Cover (1) Ball Plunger (1) Spring (1) Angle Indicator (1) Ball 12 MM (1) Knob (1) Dust Cap (4) Handle Assembly (1) Bracket (1) Switch Housing (1) Brush Cap (Pair) Counter Weight (1) Table (1) Table Insert (1) Pivot Shaft (1) Air Hose (1) Bevel Scale (1) Base Assembly (1) Knob (1) Speed Control Unit (1) Housing (1) Housing Cover Assembly (1) Control Power Cable (1)

CODE NO. 58 58/90

PART NO. 2615302996 2615302997
CODE NO. 131 650/13 650/810 823
PART NO. 2615296770 2610914361
DESCRIPTION Screw (7) Bellow (1) Retainer (2) Screw (3) Upper Arm (1) Screw (15) Screw (6) Lower Arm (1) Screw (1) Collar (2) Screw (2) Screw (2) Screw (2) Nut (2) Nut (3) Spring Clip (1) Blade Box (1) Hinge (1) Lower Clamp Bolster (1) Linkage Bar (1) Spring (1) Upper Clamp Bolster (1) Spacer (1) Spacer (1) Switch Plate (1) Hex Wrench 5.0 mm (1) Hex Wrench 3.0 mm (1) Motor Assembly (1) Brush Spring (Pair) Housing Set Assembly (1)
WRITE FOR CURRENT PRICESNO C.O.D.S
COMMANDEZ PAR LE NUMRO DE LA PICENON PAR LE NUMRO DE CODE
N DE PICE 2615302972 N DE PICE 2615302971 2610909182

2610914356

N DE CODE N DE CODE 58 58/90 N DE PICE DESCRIPTION Sous-ensemble de lampe (1) Light Bulb 25 W (1) Barre de support (1) Capot de lame (1) Support de liaison (1) Sous-ensemble du porte-lame (2) Rondelle (4) Rondelle (1) Ensemble de sige de palier (1) Rondelle (1) Rondelle (1) Rondelle (4) Rondelle (1) Rondelle (4) Rondelle (1) Rondelle (1) Rondelle (1) Rondelle (1) Boulon (4) Boulon (1) Boulon (2) Boulon (1) Boulon (1) Bouton (1) Bouton (1) Vis de blocage (1) Vis evec rondelle (3) Vis evec rondelle (1) Vis evec rondelle (3) Vis (1) Tuyau PVC (1) Botier du ventilateur (1) N DE CODE 131 650/13 650/810 823

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TOOLS & TECHNIQUES SERIES

December 2003

Tool Review

Benchtop Scroll Saws

What separates the good from the bad? Five popular models are put to the test in this tool review from Workbench magazine.

From Workbench Magazine

All rights reserved

page 1 of 7

2003 August Home Publishing
One copy for personal use. Other copies prohibited.
ew operations in a woodshop inspire creativity or offer instant gratification the way scroll sawing does. No matter how many times I sit down to scroll some intricate detail for a project, or even to create an entire project on the scroll saw, it never feels like production work. In short, scroll sawing is an escape from some of the more mechanical procedures of woodworking.As such, it's important that your scroll saw be a comfortable and dependable tool that you look forward to using. It should be easy to set up and a pleasure to operate. It should also have well-placed controls that let you focus on those all-important project details. Considering those qualities, we put five popular scroll saws through their paces.The saws we looked at are 16" models (that is, there's 16" between the blade and the body of the saw).We chose this size because of the number of saws available and the relatively affordable prices of the machines.The five saws we tested range in price from $100 to $210.
One of the most important test criteria was the vibration of the saws and how that impacted the quality of a cut.The pistoning action of the upper arm on a scroll saw makes for an inherently "shaky" tool. Saws that dampen the vibration make it much easier to follow the fine lines of a scroll pattern. We also considered how easy it is to change blades, make bevel adjustments, and operate the power and speed controls without losing focus on the workpiece.Those features ultimately became the Details That Make a Difference, which are explained on the next page.

page 2 of 7

Convenient Controls
Top-mounted controls (versus under the table) are easy to locate and adjust without losing your concentration on the workpiece.They also offer a more universal fit for right- or left-handed users when compared to controls mounted on one side or the other.

Knuckled Air Hose

Air hoses with knuckles allow a wide range of adjustment, which lets you place the blower tip where it will do the most good.

HoldDown

Left/Right Table Bevel

Stock Hold-Down

Hold downs should be easy to adjust (no tools required) with a full range of motion and a clear sight line.
Tables that tilt left and right (instead of just left) offer greater flexibility in the way you make beveled cuts. But we discovered another benefit to tables that tilt both ways. Changing blades on the saws with right- and lefttilting tables was easier because, with the table tipped to the right, theres more room to access the blade clamp.

Blade Changing

Mounting a blade in these saws was quite different from one machine to the next. So different, in fact, that we cant point to one saw and say it has the perfect system. The type of controls, where they are located, and how much space there is to operate them all influenced our opinion of blade changing.Weve explained the pros and cons of each configuration in the individual saw write-ups.

Blade Tensioning Lever

Work Light
We prefer saws that are equipped with a light, or at least have some provision for adding one as an accessory. The Wilton and Dremel saws came with worklights. Ryobi offers a light as an accessory for their saw.
Blade Clamp Locking Lever

Pin-end vs. Plain-end

Another important factor in choosing a scroll saw is whether a saw accepts pin-end blades, plain-end blades, or both. Both is the best, naturally. But each type of blade has its merits. Pin-end blades are popular with beginning scrollers because theyre easy to install. Their downfall is that they are available in a limited variety of tooth patterns. Plain-end blades, while trickier to install, are available in a wide variety of tooth patterns. Theyre also better suited to pierce cuts since they have no pins to get in the way as you thread the blade through a hole in the workpiece.

PIN-END BLADE

PLAIN-END BLADE
Pin-End Blades rest on notches in arm bracket
Plain-End Blades clamp in bracket with an Allen screw, lever, or knob

page 3 of 7

Craftsman 21610
Price: Motor: Weight: SPM Range: Blade Type: Blade Stroke: Warranty: $139.99 1.4 amp 53 Lbs 400-1,600 Plain/Pin 7 " /year
Virtues: Top-mounted controls; L/R tilting table w/dial settings. Vices: No worklight. Verdict: Best of class, based on price and performance.
www.Craftsman.com 800-549-4505
The Craftsman 21610 has some of the most worthwhile features in this group of scroll saws.The power and speed control are not only located on top of the machine, which we prefer for convenience and safety to controls mounted under the table, but theyre also large and easy to use. The table bevel and lock operation is another big plus for this saw (Fig. 1). It operates with a two-stage dial.The outer collar of the dial
adjusts the table, the inner dial locks it in the desired position.This, combined with the large angle scale, make it easy to fine-tune the table to an exact setting. The bevel system also has detent stops at 0, 15, 30, and 45. The table itself is cast steel, providing a flat, solid worksurface.The base of the saw is also cast.Together these two components contribute significantly to the solid heft of the machine, which does a great deal to dampen the vibration and make this a smooth running saw.
Changing blades on the Craftsman is relatively easy, using both plain- and pin-end blades, thanks to large tightening knobs on the blade holders. The operation could benefit from a little more space to get at the lower blade holder. This saw also has a knuckled dust blower hose, which is good. But we found it to be even more useful when we removed the bracket that holds the blower to the upper arm housing (Fig. 2). All in all, we found the Craftsman to have the right combination of features, performance, and price to award it our Editors Choice.

{ A two-stage dial adjusts and locks the bevel of the table. A large, easy-to-read scale and detents make accurate setup effortless.
{ Large, overmolded knobs, an oversized, open hold-down, and an articulating hose are among the many stand-out features of the Craftsman saw.

page 4 of 7

Delta SS350
Price: Motor: Weight: SPM Range: Blade Type: Blade Stroke: Warranty: $199.amp 60 lbs 600-1,650 Plain only

3/ " 4

2 years
Virtues: Smooth running; Quick-change blade system; Vices: Troublesome dust bin Verdict: Good performance, but with a high price.
www.DeltaWoodworking.com 800-438-2486
The Delta SS350 is a top-notch scroll saw with many outstanding features. But there are a couple things about this saw that had us scratching our heads. On the upside, this is a stout machine that does a nice job of negating vibration, so it runs and cuts quite smoothly. Only at the highest speeds was it necessary to secure the saw to keep it from walking. Once secured to a bench, vibration became a non-issue. This saw also has excellent blade changing manners.Thats thanks to Deltas Quickset II Blade Chuck System, which uses quick-release
levers instead of the typical knobs. And this saw has the blade tensioning lever located right up front on the saw (Fig. 1). We also liked the hold-down foot on this saw. Its easy to adjust for both flat and bevel work and effective at stabilizing any size workpiece. The knocks we have to give the Delta arent serious, but were enough to cost it the top spot in the test. First is the table it only tilts left, which limits the saws versatility compared to those with tables that tilt both directions. One more feature that could be improved is the dustbin (Fig. 2).The
container is effective at collecting dust, but it must be removed to tilt the table. Another oddity of the dustbin is the vacuum port.The port is supposed to twist off for attaching a hose. The cap on our saw wasnt coming off unless we cut it off. But overall, this saw is a top performer with great features. A few quirks and a relatively high price put it in the runner-up spot in this test.
} The dust bin must be removed to tilt the table. A cap on the dust port refused to spin off for us the way it was intended.

Dust Bin Dust Port

{ TTTDeltas blade tensioning and locking system uses quick release levers instead of knobs.

page 5 of 7

Dremel 1680
The Dremel 1680 offers solid performance and a number of excellent features. The high price, however, cost it a couple positions in our final ranking. Where this saw truly distinguishes itsef is in blade changing. In particular, operating the lower blade holder is especially nice because of the generous space created by tilting the table to the right and removing the storage compartment (see Photo, below right). In terms of performance, this saw marks the middle ground.Vibration at high speeds was slightly more pronounced than in the heavier saws (Craftsman and Delta), but was tolerable with the saw fastened to a workbench. With the vibration thusly dampened, cutting was noticeably smoother. As for details, Dremel got those all right, including topmounted controls, an articulating hose, dual-bevel table, a worklight, a good holddown, and it takes both blade types. Considering all that, wed never call the Dremel 1680 a bad investment its just a sizable one. Price: Motor: Weight: SPM Range: Blade Type: Blade Stroke: Warranty: $209.99 1.4 amp 40 lbs 500-1,600 Plain/Pin 3/ " years
Virtues: Top-mount controls; Worklight; Hold-down foot. Vices: Worklight is dim. Verdict: An excellent saw, but at a premium price.
www.Dremel.com 800-437-3635
{ Dremels right-tilting table creates abundant space to access the lower blade holder.

Ryobi SC164VS

The Ryobi SC164VS is an affordably priced scroll saw that sacrifices some of the qualities of its more expensive counterparts,but still offers a good starting point with some growth potential. That growth potential is evident in the fact that this saw accepts both pin- and plain-end blades. So even if you buy it as a beginner, you wont be limited by blade choices. The base saw can also be improved by adding Ryobis accessory worklight.Wed prefer to have it included, but at this price,we dont mind adding it later. Of course, there are more meaningful sacrifices. Vibration is quite pronounced in this lightweight machine. Even when bolted down, it was nearly insufferable at the highest speed setting, forcing us to moderate the speed for the smoothest possible cuts. A fixed air hose, a table that tilts only to the left, and controls mounted below the table are a few more compromises that come with the Price: Motor: Weight: SPM Range: Blade Type: Blade Stroke: Warranty: $99.97 1.2 amp 28 lbs 400-1,600 Plain/Pin 7/ " years
dust blower. Verdict: Entry-level scroll saw at a budget price. www.RyobiTools.com 800-525-2579
Virtues: Affordable price. Vices: Tensioning knob; Fixed
Ryobis bargain price. Just the same, we consider the Ryobi SC164VS a Top Value with a retail price thats under $100, and a worthwhile choice for the entrylevel scroller.

page 6 of 7

Wilton 99166
Price: Motor: Weight: SPM Range: Blade Type: Blade Stroke: Warranty: $109.99 1.2 amp 33 Lbs 500-1,700 Pin only 7/ " years The Wilton 99166 is a valuepriced scroll saw with a mixed bag of strengths and weaknesses. The performance is adequate, but its essential that this lightweight saw be fixed to a workbench when running at higher speeds. Even then, we found it necessary to reduce the speed to keep vibration at a workable level so that we could stay true to the cut lines. A couple of pluses for this saw are a fully adjustable worklight thats standard equipment and a unique power and speed control mechanism. We dont care for the location of the control, but having both functions combined in a single knob is convenient (Photo, left).
Hold-down foot is too large. Verdict: Very basic saw at a bargain price. www.WiltonTool.com 800-519-7381 >T A single knob controls the power and speed of the Wilton 99166 scroll saw.
Virtues: Controls; Worklight. Vices: Fixed dust blower;

SCROLL SAW RATINGS

SET-UP Model CRAFTSMAN DELTA DREMEL RYOBI WILTON PERFORMANCE FIT & FINISH
Table Base Table Blade Blower Hold-down Vibration Controls Tilt Change On/Off Foot

A+ B A C C

B B B A A+ A C C C C

A A A B D

B B B C C

A B A C A

B A B C C

A A A C C

One problem we do have with this saw is its uneccessarily tall holddown.As far as we can tell, that extra height doesnt do anything but obstruct the view of the cut line. Other limitations include a fixed dust blower, pin-end-only blade capacity, and a table that tilts only to the left. In general, the Wilton scroll saw is best suited to the occasional user with no plans for exploring advanced techniques requiring plainend blades. Fortunately, the reasonable price makes it an attractive tool for beginning scrollers.

Final Recommendations

Editors Choice

CRAFTSMAN 21610

Solid construction, top-rate performance, and some excellent features earned Craftsman the top spot among these scroll saws. The remarkably fair price makes it an even more obvious choice for scrollers of any skill level.

Top Value

For the truly budgetconscious woodworker, or for just occasional use, Ryobi is a good way to get an affordable start in scroll sawing while still having the versatility of using both pin-and plain-end blades.

page 7 of 7