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I have a Dewalt 788 that I've had for a few years and absolutely love but I'm having a real problem with my blades. I've seen lots of posts about blades not staying in the bottom holder but I've not seen any adressing the problem I'm having. When I tighten the blade at the bottom it kinks the blade quite badly so that after the first or second cut I have a real problem threading it through the pilot hole. In some cases I can drill larger holes but in many instances I'm doing very small areas and can't make the holes larger. I've taken the thumb screw out and made sure that the end of it is flat and I've adjusted the screw or whatever it's called on the other side so that they meet in the middle (or at least it looks like it does, it's kind of hard to tell under there). I've tried having more of the blade extending at the top holder and just enough at the bottom to hold it but it still kinks. I sure would appreciate any help you could offer me as I'm having to throw perfectly good blades away when they get so kinked I can't get them through the holes or after being bent many times the end breaks off and eventually the blade becomes too short to use

. Sorry for the long post but trying to explain a problem when you're technically challenged is difficult. I hope I've explained well enough to get the answer I need. Thanks in advance. Carole

I experienced this problem shortly after I got my Dewalt about 3 years ago.

As the bottom blade holder turns into the blade, the blade bends toward you. It does not happen in the top blade holder as the turning action pushes the blade into the back of the holder giving it support. The thumbscrew face is an insert in that is supposed to rotate while tightening preventing this from happening but it still does.

My solution was to get an additional thumbscrew and replace the bottom set screw with the additional thumbscrew therefore having two rotating surfaces when tightening the lower blade holder, and haven't had the problem since. I put a dab of Loctite on it so it stays in place.

Thanks so much for your quick response to my problem. Do you think I'd be able to get another thumbscrew at the tool warehouse where I bought the saw or can you get them at any good hardware store? Also I really appreciate the photo as it helped explain the problem/solution. Thanks again! Carole

I doubt you would be able to get them locally.

I got mine directly from Dewalt at http://www.dewaltservicenet.com/ServiceNet

Part Number is 286303-00

If you order I would get at least 2 so I would have a replacement on hand in case you need one for either the top or bottom.

Oops that link don't work -try this one.

Thanks, you have been such a great help. I've ordered the part and I'm now I'm anxious to get it. I'm doing a picture of a '55 Chevy and the grill alone must have (no exageration) about 120 cutouts. I ordered a new batch of FD blades from Mike so I should be all set! I'm looking forward to blades with no kinks thanks to you. Carole

Carole, I worked at the GM factory for a short time here in Janesville WI many years ago. I helped build a number of 55 Chevy's. Would sure like to see a picture of your cutting when you finish.

Mick, I'm still working on the '55 but I just finished a cutout of my husbands '56 Chevy pickup you might be interested in. I made the pattern for it myself and although I'm not overly fond of doing vehicles I'm really pleased with the outcome. I should have taken this picture before I put the glass in the frame but I'll take another picture when I frame the second one. I always cut at least two of everything I do and this way he has one for his office and one for home. Carole

Have 788 also, and had the same problem awhile back. First you have got to get the screws that hold the blade

abit aways from the edge......you the thumb screw on your right and and allen screw on the left make sure that the

allen is out away from the edge. You need to take both screws out and us a file or sandpaper and clean the ends up,

don't take a lot of material off just enough to make them flat. The other thing is don't over tighten the thumb screw, just

use enough pressure to hold the blade. If all this fails go to either in person or online to a DeWalt factory store and order

a new set of screws. Hope this helps you

Thanks Bill, I've fooled with the thumbscrew and the allen screw to no avail so I've ordered another thumbscrew to replace the allen screw in hopes that that will solve the problem. Thanks so much for your help it sure is nice to know there are people out there willing to help others. I'll keep you posted on the results. Carole

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