Dewalt Dw872 Review

The DEWALT DW872 Multi-Cutter Saw is, simply put, a workhorse designed for serious metal fabrication and cutting applications.

If you’re tired of abrasive chop saws that burn through blades and create a shower of sparks, the DW872 offers a game-changing alternative with its carbide-tipped blade, delivering cleaner, cooler, and faster cuts.

This machine is built for precision and durability, making it an excellent investment for workshops, contractors, and DIY enthusiasts who demand high performance and longevity from their tools.

Its ability to slice through various metals with minimal burr and heat sets it apart from traditional methods, significantly improving both efficiency and safety in the workplace.

Here’s a comparison of the DEWALT DW872 with some other notable metal cutting tools:

• DEWALT DW872 Multi-Cutter Saw

  

  • Key Features: 14-inch carbide-tipped blade, 15-amp motor, dry-cut technology, quick-adjust fence, horizontal D-handle.
  • Average Price: $400 – $500
  • Pros: Exceptionally clean, cool, and fast cuts. long blade life. minimal sparks. precise angle adjustments. durable construction.
  • Cons: Higher initial cost than abrasive chop saws. heavier. blade replacements can be pricey.

• Milwaukee 6177-20 Abrasive Chop Saw

  • Key Features: 14-inch abrasive wheel, 15-amp motor, quick-adjust vise, spark deflector.
  • Average Price: $150 – $200
  • Pros: Very affordable. good for rough cutting. widely available abrasive wheels.
  • Cons: Produces significant heat and sparks. messy cuts. blades wear down quickly. less precise for finishing work.

• Makita LC1230 Metal Cutting Saw

  • Key Features: 12-inch carbide-tipped blade, 15-amp motor, D-handle, quick-release vice.
  • Average Price: $350 – $450
  • Pros: Similar dry-cut benefits to the DW872. good portability. clean cuts.
  • Cons: Slightly smaller blade diameter limits cutting capacity compared to DW872. blade can be expensive.

• Evolution S355CPS Steel Cutting Chop Saw

  • Key Features: 14-inch TCT blade, 15-amp motor, cold-cut technology, integrated chip collection.
  • Average Price: $400 – $550
  • Pros: Excellent for steel, good chip collection reduces mess. minimal heat and sparks.
  • Cons: Can be louder. some users report blade longevity issues with very hard materials if not used correctly.

• RYOBI 14-inch Abrasive Chop Saw

  • Key Features: 14-inch abrasive wheel, 15-amp motor, adjustable vise, spark deflector.
  • Average Price: $100 – $150
  • Pros: Extremely budget-friendly. good for occasional, rough cuts. lightweight.
  • Cons: Lower build quality. typical abrasive saw drawbacks heat, sparks, mess. less durable for heavy use.

• JET J-2114 Metalworking Bandsaw

  • Key Features: Variable speed, coolant system, horizontal/vertical operation, precise cutting.
  • Average Price: $1000 – $2000 benchtop models
  • Pros: Highly accurate and smooth cuts. ideal for intricate shapes. quiet operation. long blade life with coolant.
  • Cons: Much higher price point. slower cutting speed than chop saws for straight cuts. larger footprint.

• Plasma Cutter

  • Key Features: Uses high-temperature plasma to cut conductive materials, portable units available.
  • Average Price: $500 – $2000 depending on power
  • Pros: Excellent for sheet metal and irregular shapes. fast cutting. relatively portable.
  • Cons: Requires an air compressor. creates a wider kerf and dross. not ideal for precise straight cuts on thicker stock without guides. safety gear crucial.

Unpacking the DEWALT DW872: A Deep Dive into Design and Build Quality

Alright, let’s peel back the layers on the DEWALT DW872. When you first unbox this beast, you immediately notice its solid construction. This isn’t some flimsy piece of kit. We’re talking about a tool that feels like it’s ready to withstand years of abuse in a demanding workshop environment. The attention to detail in its design speaks volumes about its intended purpose: serious metal fabrication.

Robust Frame and Base for Stability

The DW872 features a heavy-duty steel base that provides exceptional stability during operation. This isn’t just for show. stability is critical for safety and precision when cutting metal.

• Reduced Vibration: The robust base significantly dampens vibrations, leading to cleaner cuts and less tool fatigue.
• Workpiece Support: Its wide stance offers better support for longer workpieces, preventing wobble and ensuring consistent cut quality.
• Portability within limits: While heavy, the integrated carrying handle makes it manageable for two people to move, or for one strong individual to shift across a shop floor. It’s not a tool you’ll casually toss in the back of your truck, but it’s designed to be relocated when necessary.

Ergonomic D-Handle and Trigger

DEWALT clearly put thought into user comfort, especially for a tool that might see prolonged use.

• Comfortable Grip: The horizontal D-handle is designed for a natural, comfortable grip, reducing strain on the wrist and arm. This ergonomic design is crucial for maintaining control during cuts.
• Ambidextrous Use: The handle design generally accommodates both left and right-handed users, though the trigger placement might feel slightly more natural for right-handers.
• Safety Trigger: The trigger mechanism includes a safety lockout, preventing accidental starts. This is a standard but vital feature for any power tool, especially one with a 14-inch spinning blade.

Integrated Vise and Fence System

The heart of precise cutting lies in the clamping mechanism and fence.

The DW872 shines here with a well-thought-out system. True Residential Treadmill

• Quick-Adjust Vise: This vise is a standout feature. It allows for rapid clamping and releasing of material, significantly speeding up workflow, particularly when making repetitive cuts. The quick-release lever is intuitive and effective.
• Adjustable Fence: The fence can be adjusted without tools for angles up to 45 degrees. This is a huge time-saver compared to saws that require wrenches for every angle change.
  • Positive Stops: The fence has positive stops at common angles e.g., 0, 45 degrees, ensuring accuracy and repeatability.
  • Material Compatibility: The vise jaws are designed to securely hold various material shapes, from square tubing and angle iron to round stock.

Power and Performance: Cutting Through Metal Like Butter

The DEWALT DW872 isn’t just built tough. it’s got the muscle to back it up.

We’re talking about a saw engineered to rip through metal with efficiency and precision that traditional abrasive chop saws can only dream of.

The core of its performance lies in its powerful motor and the innovative carbide-tipped blade system.

The Heart of the Beast: 15-Amp Motor

Underneath the hood, the DW872 houses a robust 15-amp, 4 HP max watts out motor. This isn’t just about raw power. it’s about sustained power delivery under load.

• High Torque Output: This motor is designed to deliver high torque, which is essential for maintaining blade speed when cutting through tough materials like thick steel or stainless. It prevents the blade from bogging down, leading to smoother cuts and extending motor life.
• Optimal RPM: The motor spins the 14-inch blade at a no-load speed of 1300 RPM. This specific RPM is critical for the dry-cut carbide blade technology, ensuring efficient chip removal and minimizing heat buildup.
• Thermal Overload Protection: Like many professional-grade tools, the DW872 likely incorporates some form of thermal overload protection, which prevents the motor from burning out if it’s pushed too hard for too long. This feature safeguards your investment.

Dry-Cut Technology and Carbide-Tipped Blade Advantage

This is where the DW872 truly differentiates itself from standard abrasive chop saws. Best Way To Cook On A Gas Bbq

• Carbide-Tipped Blade: Instead of an abrasive wheel that grinds material away, the DW872 uses a carbide-tipped blade that effectively “saws” through metal, creating chips instead of dust. This results in:
  • Cooler Cuts: Significantly less heat is generated, meaning the workpiece remains cooler to the touch, reducing the risk of material distortion or discoloration. This is particularly important for welding or fabrication where heat-affected zones need to be minimized.
  • Cleaner Cuts: The cuts are remarkably smooth with minimal burr, often requiring little to no post-cut finishing. This saves time and effort.
  • Faster Cuts: Because it’s actually cutting rather than grinding, the DW872 can often slice through material much quicker than an abrasive saw, especially thicker stock.
  • Minimal Sparks: Instead of a dangerous shower of sparks, you get hot metal chips that fall mostly downwards, dramatically improving safety in the workshop environment.
• Blade Longevity: While the initial cost of a carbide blade is higher, its lifespan is significantly longer than multiple abrasive wheels, often lasting hundreds of cuts on steel before needing sharpening or replacement. This translates to lower long-term operating costs and less downtime.

Cutting Capacity and Versatility

The DW872’s design allows it to handle a surprising range of material sizes and types.

• Maximum Cutting Capacity:
  • Square Stock 0°: Typically up to 4-1/2 inches.
  • Rectangular Stock 0°: Can vary, but often around 6-1/2 inches by 4-1/2 inches.
  • Round Stock 0°: Up to 5 inches.
  • Angles 45°: Capacities are reduced for miter cuts, but still substantial for common fabrication needs. For example, 45-degree cuts on square stock might be around 3-1/2 inches.
• Material Types: The DW872 excels at cutting:
  • Mild Steel: Angle iron, square tubing, flat bar, rebar, channel.
  • Stainless Steel: With the appropriate blade and technique, it handles stainless very well.
  • Aluminum: While it can cut aluminum, it’s crucial to use a specific non-ferrous carbide blade to prevent gumming up and ensure clean cuts.
  • Copper & Brass: Similar to aluminum, dedicated blades are recommended.
• Applications: Ideal for welding shops, metal fabrication, construction sites, automotive repair, and serious home workshops dealing with metal projects.

Safety Features: Built-In Protection for Peace of Mind

When you’re dealing with a tool that spins a 14-inch carbide blade at 1300 RPM, safety isn’t just a recommendation. it’s paramount.

DEWALT has integrated several critical safety features into the DW872 to protect the operator and the immediate environment.

Blade Guard and Spark Deflector

These are your first lines of defense against debris and the cutting action itself.

• Retracting Blade Guard: The DW872 features a sturdy, retracting blade guard that covers the blade when not in use and automatically pulls back as you initiate a cut. This design significantly reduces exposure to the spinning blade.
  • Durability: The guard is typically made from robust material, designed to withstand the occasional impact from flung chips.
  • Visibility: While providing protection, it’s designed to offer a clear view of the cutting line, which is crucial for accuracy.
• Chip/Spark Deflector: Although the DW872 produces far fewer sparks than an abrasive saw, it does generate hot metal chips. The integrated deflector helps direct these chips downward and away from the operator, minimizing the risk of burns or eye injuries.

Quick-Release Vise and Material Clamping

A securely clamped workpiece is a safe workpiece. Best Chiropractic Massage Gun

The DW872’s clamping system contributes directly to operator safety.

• Secure Grip: The quick-release vise ensures that the material is held firmly in place, preventing it from shifting, binding the blade, or being violently ejected during the cut. A loose workpiece is a primary cause of kickback and injury.
• Reduced Hand Proximity: By allowing for fast and secure clamping, operators can keep their hands further away from the blade during the actual cutting operation.
• Versatile Clamping: The vise’s ability to hold various stock shapes round, square, rectangular securely means you’re less likely to improvise unsafe clamping methods.

Overload Protection and Controlled Start-Up

Protecting the tool often means protecting the user.

• Motor Overload Protection: While not always overtly advertised as a “safety feature,” thermal overload protection on the motor prevents overheating, which can lead to tool failure and unpredictable behavior. A smoothly operating tool is a safer tool.
• Soft Start Implied/Benefit: While the DW872 isn’t explicitly marketed with a “soft start” feature like some other tools, the nature of its motor design and the carbide blade generally lead to a more controlled engagement than the violent jerk of some abrasive saws. This reduces sudden torque on the operator’s hands and arms.

Importance of Personal Protective Equipment PPE

No tool, regardless of its built-in safety features, can replace proper PPE. When operating the DW872, you should always wear:

• Safety Glasses/Face Shield: Crucial for protecting against flying metal chips.
• Hearing Protection: Even though it’s quieter than an abrasive saw, prolonged exposure can still cause hearing damage.
• Heavy-Duty Gloves: To protect hands from sharp edges of cut material and potential hot chips. Avoid loose-fitting gloves that could get caught in the blade.
• Appropriate Clothing: Avoid loose clothing or jewelry that could snag on moving parts. Long sleeves can offer some protection against chips.
• Ventilation: Ensure adequate ventilation to clear any metal dust or fumes generated, especially when cutting certain alloys.

Maintenance and Blade Life: Keeping Your Investment Sharp

Like any high-performance tool, the DEWALT DW872 benefits from regular maintenance to ensure optimal performance, extend its lifespan, and maximize the life of its expensive carbide blades. Think of it like taking care of a sports car. a little attention goes a long way.

Blade Care and Sharpening

The carbide-tipped blade is the heart of the DW872’s cutting prowess, and its proper care is paramount. Osaki Massage Chair Replacement Parts

• Cleanliness: Regularly clean the blade to remove accumulated metal chips and debris. A brass brush or compressed air can be effective. Built-up material can lead to less efficient cutting, increased heat, and potential blade damage.
• Inspection for Damage: Before each use, inspect the carbide tips for any signs of chipping, cracking, or missing teeth. A damaged blade can be dangerous and will produce poor cuts.
• Resharpening: Unlike abrasive wheels, carbide blades can be sharpened. This is a specialized service, and it’s crucial to send your blades to a reputable sharpening service that specializes in carbide saw blades.
  • Cost-Effectiveness: Sharpening is significantly cheaper than buying a new blade, making it a smart economic choice.
  • Number of Resharpenings: A good quality blade can often be resharpened multiple times before it needs to be replaced, extending its overall service life considerably.
• Proper Blade Selection: Always use blades specifically designed for dry metal cutting with the correct tooth count for the material you are cutting. Using the wrong blade can lead to premature wear, poor cuts, and even damage to the saw.

General Cleaning and Lubrication

Keeping the saw clean and properly lubricated is essential for smooth operation.

• Regular Cleaning: After each use, or at least at the end of the day, wipe down the saw to remove metal dust and chips. Pay particular attention to the vise, fence, and the area around the blade. Metal dust can be abrasive and cause premature wear on moving parts.
• Vise and Pivot Points: Apply a light lubricant e.g., silicone spray, dry lubricant, or a light machine oil to the moving parts of the quick-release vise and the pivot points of the saw head. This ensures smooth adjustments and prevents seizing.
• Compressed Air: Use compressed air periodically to blow out any dust or debris from vents and hard-to-reach areas. Always disconnect the saw from power before cleaning.

Motor and Electrical Care

While the motor is generally maintenance-free, some checks are advisable.

• Ventilation Ports: Ensure the motor’s ventilation ports are free from obstruction. Blocked vents can lead to overheating and premature motor failure.
• Power Cord Inspection: Regularly inspect the power cord for any signs of damage, fraying, or exposed wires. Replace damaged cords immediately.
• Carbon Brushes if applicable: Some universal motors use carbon brushes that wear down over time. While modern DEWALT tools often feature brushless motors or long-life brushes, if your model has accessible brushes, consult the manual for inspection and replacement intervals.

Storage

Proper storage protects the saw from environmental factors.

• Dry Environment: Store the DW872 in a dry environment to prevent rust, especially on the cast iron or steel components.
• Covering: If storing for an extended period, consider covering the saw to protect it from dust and debris.

By adhering to these maintenance practices, you’re not just ensuring your DW872 runs smoothly.

You’re also protecting a significant investment and ensuring it continues to deliver precise, efficient cuts for years to come. Kahuna Massage Chair Repair

Applications and Use Cases: Where the DW872 Shines

The DEWALT DW872 isn’t just another power tool.

It’s a specialized piece of equipment that truly excels in specific environments and for particular tasks.

Its dry-cut technology and robust design make it indispensable for professionals and serious hobbyists who regularly work with metal.

Metal Fabrication Shops

This is arguably the natural habitat for the DW872. In metal fabrication, precision, speed, and finish quality are paramount, and the DW872 delivers on all fronts.

• Cutting Stock Materials: Ideal for quickly and cleanly cutting various stock materials like angle iron, square tubing, flat bar, channel, and round bar to specific lengths for projects.
• Welding Prep: The cool, burr-free cuts significantly reduce the amount of time spent grinding and deburring before welding. This leads to stronger, cleaner welds and faster project completion.
• Fixture and Jig Construction: For creating accurate components for jigs and fixtures, the DW872’s precise miter cutting capabilities are invaluable.
• Repetitive Cuts: Its quick-adjust vise makes it efficient for repetitive cutting tasks, saving time and labor on large batch jobs.

Construction and Job Sites

While heavy, the DW872’s performance benefits often outweigh its portability challenges on job sites. Milwaukee Adjustable Wrench Review

• Structural Steel Cutting: Cutting steel beams, columns, or rebar quickly and cleanly on-site.
• HVAC Ductwork: Efficiently cutting galvanized steel or aluminum for ducting applications.
• Framing: For steel stud framing, it offers faster and cleaner cuts than traditional methods.
• Pipe Fitting: Precision cuts for pipes in plumbing or industrial applications, especially when clean edges are critical for proper sealing or welding.

Automotive and Chassis Fabrication

For those working on custom car builds, roll cages, or suspension components, the DW872 is a must.

• Roll Cage Tubing: Delivers clean, precise cuts on chromoly or mild steel tubing, which is essential for strong and safe roll cages.
• Frame Repairs: Accurately cutting sections for frame repairs or modifications.
• Exhaust Systems: Clean cuts on exhaust tubing for custom builds or repairs.
• Bracket Fabrication: Quickly producing custom brackets and mounts with clean edges.

Educational Institutions and Vocational Schools

The DW872 is an excellent tool for teaching metalworking due to its safety features and precision.

• Hands-On Training: Provides students with experience using industrial-grade metal cutting equipment.
• Safer Environment: Compared to abrasive saws, the reduced sparks and heat contribute to a safer learning environment, while still demonstrating effective metal cutting.
• Project Work: Enables students to produce professional-looking metal projects.

Home Workshops and Serious DIY Enthusiasts

If you’re a serious hobbyist who frequently works with metal, the DW872 is a worthwhile investment.

• Gate and Fence Building: For fabricating custom gates, fences, or railings with precise joints.
• Shop Furniture/Workbenches: Building heavy-duty metal workbenches or carts that require robust frames.
• Artistic Metalwork: For sculptors or metal artists who need precise and clean cuts on various metal stocks.

In essence, if your projects involve frequent, precise, and clean cuts on metal, the DEWALT DW872 offers a significant upgrade over traditional methods, delivering superior results with enhanced safety and efficiency.

DEWALT DW872 vs. Abrasive Chop Saws: The Clear Difference

This is where the rubber meets the road. Best Charcoal Grilling Tips

If you’ve been using an abrasive chop saw for your metal cutting needs, understanding the fundamental differences and superiorities of the DEWALT DW872 is crucial. It’s not just an incremental improvement. it’s a paradigm shift in how you cut metal.

Cutting Mechanism and Heat Generation

The most significant distinction lies in how they cut.

• Abrasive Chop Saw: These saws use a bonded abrasive disc like a giant grinding wheel that grinds through metal.
  • Heat: This grinding action generates immense heat, causing the workpiece to become very hot, often glowing red. This heat can distort thin material, discolor stainless steel, and create a significant heat-affected zone HAZ that can weaken welds or alter material properties.
  • Sparks: They produce a spectacular, dangerous shower of hot sparks that fly everywhere, posing a serious fire hazard and requiring extensive cleanup.
  • Material Removal: Material is removed as fine dust, which is hazardous to breathe and creates a considerable mess.
• DEWALT DW872 Dry-Cut Multi-Cutter Saw: This saw employs a carbide-tipped blade that saws or mills through metal, creating chips.
  • Heat: The cutting action generates significantly less heat. The workpiece remains cool enough to touch almost immediately after the cut, preserving material integrity and reducing the risk of distortion.
  • Sparks: It produces minimal sparks, instead generating hot metal chips that tend to fall straight down into the integrated chip collection tray or onto the ground nearby. This dramatically reduces fire risk and cleanup.
  • Material Removal: Material is removed as larger, manageable chips, which are easier to clean up and less hazardous to inhale than fine abrasive dust.

Cut Quality and Finish

This is where the DW872 truly shines for anyone concerned with the end product.

• Abrasive Chop Saw:
  • Rough Edges: Cuts are typically very rough, with a significant burr that often requires extensive grinding, filing, or deburring.
  • Accuracy: Maintaining precise angles can be challenging due to blade deflection and the rough nature of the cut.
  • Kerf: The cut width kerf can be relatively wide.
• DEWALT DW872:
  • Clean, Smooth Edges: Cuts are remarkably clean, smooth, and precise, with minimal to no burr. This often eliminates the need for secondary finishing operations, saving significant time and labor, especially crucial for welding preparation.
  • Accuracy: The rigid blade and precise fence system allow for highly accurate and repeatable angle cuts.
  • Cool to Touch: The cut edges remain cool, making handling safer and faster.

Blade Life and Operating Cost

The initial cost comparison can be misleading.
* Blade Cost: Abrasive wheels are inexpensive individually.
* Blade Life: However, they wear down very quickly, often requiring multiple blade changes for a single project, especially on thicker materials.
* Operating Cost: While each blade is cheap, the sheer volume of blades consumed, plus the labor time for deburring and cleanup, makes the overall operating cost surprisingly high over time.
* Blade Cost: Carbide-tipped blades are significantly more expensive upfront e.g., $80-$150+ per blade.
* Blade Life: One carbide blade can last for hundreds, even thousands of cuts on mild steel before needing resharpening or replacement. A single blade can easily outlast dozens of abrasive wheels.
* Operating Cost: While the initial blade cost is higher, the extended lifespan, the ability to resharpen, and the reduced time spent on finishing work often lead to a lower total cost of ownership over the long run.

Speed and Efficiency

For production environments, speed is money. Smart Home Robot Vacuum

• Abrasive Chop Saw: Cuts can be relatively slow, especially on thicker materials, as you often have to “grind” through the material.
• DEWALT DW872: Cuts are significantly faster, particularly on thicker sections, because the blade is actually cutting material away efficiently. This translates directly to increased productivity.

In summary, while an abrasive chop saw might be a cheaper entry point for occasional, rough cuts where finish and heat don’t matter much, the DEWALT DW872 is a superior tool for anyone needing clean, fast, precise, and cooler cuts on metal, resulting in higher quality output, improved safety, and often lower long-term operating costs. It’s an investment in efficiency and professionalism.

Accessorizing Your DW872: Essential Add-ons for Enhanced Performance

Just like a well-equipped workshop isn’t complete with just the main tools, getting the most out of your DEWALT DW872 often involves adding a few key accessories. These aren’t just luxuries.

They can significantly improve performance, safety, and overall efficiency, turning an already great saw into an indispensable workhorse.

Specialized Blades for Different Materials

While the stock blade is excellent for mild steel, expanding your blade arsenal opens up new possibilities.

• Non-Ferrous Metal Blades: These blades have a different tooth geometry often more teeth, different rake angle specifically designed for cutting softer metals like aluminum, copper, brass, and even plastics. Using a ferrous blade on non-ferrous metals can cause gumming, poor cuts, and premature blade wear.
  • Benefit: Prevents material buildup on teeth, provides cleaner cuts, and extends blade life when cutting soft metals.
• Thin Metal Blades: For very thin sheet metal or tubing, a blade with a higher tooth count can help reduce burring and distortion, providing an even cleaner cut.
  • Benefit: Minimizes deformation on delicate materials, leading to better aesthetics and less post-processing.
• Stainless Steel Specific Blades: While many standard carbide blades can cut stainless, dedicated stainless steel blades are engineered to handle the harder, tougher nature of stainless, often with specific coatings or tooth designs that dissipate heat more effectively and resist wear.
  • Benefit: Extends blade life and maintains cut quality on challenging stainless steel.

Roller Stands and Material Supports

Cutting long or heavy pieces of metal unsupported is not only unsafe but also leads to inaccurate cuts. Exp 7I Treadmill Review

• Adjustable Roller Stands: These stands provide essential support for long workpieces, ensuring they remain level with the saw’s cutting surface.
  • Benefit: Improves cut accuracy by preventing material sag or wobble, enhances safety by reducing material tipping, and makes one-person operation of long stock much more feasible.
• Fixed Height Supports: For dedicated setups, fixed height supports can be integrated into a workbench or custom stand to create a permanent, level cutting station.
  • Benefit: Provides consistent support for repetitive tasks, ideal for production environments.
• Outfeed Supports: Just as important as infeed support, outfeed supports prevent the cut-off piece from dropping prematurely, which can cause binding or dangerous kickback.

Dust Collection and Chip Management

While the DW872 creates chips rather than fine dust, managing these chips is still important.

• Chip Collection Tray: The integrated chip collection tray is a good start, but for heavy use, you might need to empty it frequently.
  • Benefit: Keeps the work area cleaner, reduces slips from scattered chips, and makes cleanup easier.
• Shop Vac with Metal-Rated Filter: While direct vacuum attachment isn’t always practical due to the size and temperature of chips, using a shop vac to clean up accumulated chips and larger debris around the saw is highly recommended. Ensure the shop vac is rated for metal debris or has a HEPA filter to capture fine metallic particles.
  • Benefit: Improves shop cleanliness and air quality.

Clamping Accessories

Beyond the built-in vise, additional clamps can offer extra security and versatility.

• C-Clamps or Quick Clamps: For odd-shaped materials or when you need extra clamping force, external clamps can supplement the saw’s vise.
  • Benefit: Provides additional stability for difficult workpieces, ensuring safer and more accurate cuts.
• Magnetic Squares: Useful for holding small pieces of ferrous metal at precise angles for measuring or marking before cutting.
  • Benefit: Speeds up setup and improves accuracy for small components.

Investing in these accessories not only enhances the performance of your DEWALT DW872 but also elevates your overall metal cutting experience, making it safer, more efficient, and more enjoyable.

Troubleshooting Common Issues: Keeping Your DW872 Running Smoothly

Even the most robust tools can encounter hiccups.

Knowing how to troubleshoot common issues with your DEWALT DW872 can save you time, frustration, and potentially costly repair bills. Heavy Duty 6 Person Tent

Most problems can be traced back to blade issues, material handling, or basic power supply.

Issue 1: Poor Cut Quality Burrs, Rough Edges, Slow Cuts

If your cuts are no longer clean, fast, or are producing excessive burrs, it’s almost always blade-related.

• Symptoms: Excessive burr, slow cutting speed, blade binding, increased heat, rough cut surface.
• Troubleshooting Steps:
  1. Check Blade Sharpness: This is the most common culprit. A dull blade forces the saw to “grind” rather than “cut,” leading to all the symptoms.
     • Action: Inspect carbide teeth for dullness, chipping, or missing tips. If dull, send it for professional sharpening or replace the blade.
  2. Verify Blade Type for Material: Are you cutting aluminum with a steel blade? Or thick stainless with a general-purpose blade?
     • Action: Ensure you’re using the correct blade type for the material. Non-ferrous metals require specific blades to prevent gumming.
  3. Inspect Blade for Debris Buildup: Metal chips can sometimes get caked onto the blade’s body or between teeth.
     • Action: Disconnect power, use a brass brush or compressed air to clean the blade thoroughly.
  4. Check Material Clamping: A loose workpiece can vibrate, leading to rough cuts and blade deflection.
     • Action: Ensure the material is securely clamped in the vise before cutting.
  5. Review Cutting Technique: Are you forcing the cut too quickly or applying inconsistent pressure?
     • Action: Apply steady, consistent pressure throughout the cut. Let the blade do the work.

Issue 2: Excessive Sparks and Heat Like an Abrasive Saw

If your DW872 is acting like an abrasive saw, it’s a sure sign the blade isn’t cutting properly.

• Symptoms: Bright shower of sparks more than usual chips, workpiece getting very hot, audible grinding noise.
  1. Blade Dullness/Damage: As mentioned above, this is the primary reason the blade stops cutting and starts grinding.
     • Action: Sharpen or replace the blade.
  2. Wrong Blade for Material: Attempting to cut hardened steel with a blade not designed for it can cause it to essentially act like an abrasive wheel.
     • Action: Confirm the blade is appropriate for the material’s hardness.
  3. Overheating/Overfeeding: Pushing the saw too hard too fast can generate excessive friction and heat.
     • Action: Reduce feed pressure, allow the blade to cool if needed.

Issue 3: Motor Overheating or Tripping Breaker

This indicates the motor is under excessive strain.

• Symptoms: Motor feels hot to touch, loss of power, saw suddenly stops, circuit breaker trips.
  1. Dull Blade: A dull blade makes the motor work significantly harder.
  2. Overloading the Motor: Attempting to cut material beyond the saw’s capacity or pushing too hard.
     • Action: Reduce feed pressure. Ensure the material size is within the saw’s stated capacity.
  3. Blocked Ventilation: Dust and debris can clog motor vents, preventing proper cooling.
     • Action: Disconnect power, use compressed air to clear all motor vents.
  4. Extension Cord Issues: Using an undersized or excessively long extension cord can cause voltage drop and motor overheating.
     • Action: Use a heavy-gauge e.g., 12-gauge, shorter extension cord.
  5. Internal Motor Problem: If none of the above, there might be an internal motor issue e.g., worn brushes if applicable, winding damage.
     • Action: Seek professional service from an authorized DEWALT service center.

Issue 4: Blade Wobble or Vibration

This can lead to inaccurate cuts and potential safety hazards. Human Touch Novo Xt2 Costco

• Symptoms: Excessive vibration during cuts, inconsistent kerf, loud noise.
  1. Blade Not Seated Properly: The blade might not be fully seated on the arbor or the arbor nut isn’t tightened correctly.
     • Action: Disconnect power. Loosen and re-tighten the arbor nut, ensuring the blade is flush against the inner flange. Always follow torque specifications in the manual.
  2. Damaged Blade: A bent or warped blade will cause wobble.
     • Action: Inspect the blade for any physical damage. Replace if bent.
  3. Worn Arbor or Flanges: Over time, the arbor or the blade flanges can wear, leading to play.
     • Action: Inspect these components for wear. If damaged, they may need replacement by a service professional.
  4. Loose Base/Hardware: Check if the saw’s head or base mounting bolts are loose.
     • Action: Tighten any loose bolts or screws.

By systematically going through these troubleshooting steps, you can often diagnose and resolve common issues with your DEWALT DW872, ensuring it continues to be a reliable and efficient tool in your workshop.

Remember, always consult your owner’s manual for specific instructions and safety warnings.

Frequently Asked Questions

What is the primary advantage of the DEWALT DW872 over a traditional abrasive chop saw?

The primary advantage of the DEWALT DW872 is its carbide-tipped blade and dry-cut technology, which results in significantly cleaner, cooler, and faster cuts with minimal burr and far fewer sparks compared to an abrasive saw.

Can the DEWALT DW872 cut stainless steel?

Yes, the DEWALT DW872 can cut stainless steel.

For optimal results and blade longevity, it is recommended to use a carbide-tipped blade specifically designed for cutting stainless steel. My Treadmill Is Slipping

What is the maximum cutting capacity of the DW872 for square stock?

The DEWALT DW872 typically has a maximum cutting capacity of 4-1/2 inches for square stock at 0 degrees straight cuts.

How long does a carbide-tipped blade last on the DW872?

A carbide-tipped blade on the DW872 can last for hundreds, or even thousands of cuts on mild steel, far outlasting numerous abrasive wheels, especially if cared for properly and resharpened.

Does the DW872 produce a lot of sparks?

No, the DW872 produces minimal sparks. Instead, it generates hot metal chips that mostly fall straight down, a significant safety and cleanliness improvement over abrasive saws.

Is the DEWALT DW872 a wet cut saw?

No, the DEWALT DW872 is a dry-cut saw. It does not use coolant like a wet cut saw.

Can I resharpen the carbide blades for the DW872?

Yes, the carbide-tipped blades used with the DW872 can be professionally resharpened multiple times, extending their lifespan and reducing operating costs. Insomnia Activities

What kind of motor does the DEWALT DW872 have?

The DW872 is equipped with a 15-amp, 4 HP max watts out motor, providing robust power for cutting various metals.

How does the quick-adjust vise work on the DW872?

The quick-adjust vise on the DW872 features a lever that allows for rapid opening, closing, and clamping of material, significantly speeding up setup and cutting times.

Is the DEWALT DW872 suitable for home use?

Yes, for serious DIY enthusiasts or home workshops that frequently work with metal and prioritize clean, precise cuts, the DW872 is an excellent, albeit significant, investment.

What safety features does the DW872 include?

Key safety features include a retracting blade guard, a robust material clamping vise, and chip/spark deflector to minimize operator exposure to the blade and debris.

What RPM does the DW872 blade spin at?

The 14-inch blade on the DEWALT DW872 spins at a no-load speed of 1300 RPM. Lifespan Tr1200I Treadmill Review

Can the DW872 cut aluminum?

Yes, the DW872 can cut aluminum, but it is highly recommended to use a specific non-ferrous carbide-tipped blade to prevent gumming and ensure clean cuts.

Is the DEWALT DW872 loud?

While quieter than an abrasive chop saw, the DW872 still generates significant noise when cutting metal. Hearing protection is always recommended.

What kind of burr does the DW872 leave on cuts?

The DW872 leaves minimal to no burr, often eliminating the need for secondary deburring operations, which is a major time-saver.

How much does the DEWALT DW872 typically weigh?

The DEWALT DW872 is a robust machine, typically weighing around 50-55 pounds, making it stable but not easily portable by one person for long distances.

Can I cut angle iron with the DW872?

Yes, the DW872 is excellent for cutting angle iron cleanly and precisely, including miter cuts up to 45 degrees. Best Massage Gun Cheap

What kind of cleanup is required after using the DW872?

Cleanup primarily involves sweeping or vacuuming up metal chips that fall from the cutting area, which are much easier to manage than the fine dust and excessive sparks of an abrasive saw.

Is the DW872 good for cutting thick steel?

Yes, the powerful motor and carbide blade of the DW872 make it highly effective for cutting thick steel sections quickly and cleanly.

Can I cut non-metal materials with the DW872?

While primarily designed for metal, with the correct specialized blade, it can cut certain non-metal materials like some plastics. However, it’s not its primary purpose, and caution is advised.

What maintenance does the DW872 require?

Regular maintenance includes keeping the blade clean, inspecting for damage, lubricating moving parts like the vise, ensuring clear motor vents, and inspecting the power cord.

Does the DW872 come with a blade?

Yes, the DEWALT DW872 typically comes with one general-purpose 14-inch carbide-tipped metal cutting blade suitable for mild steel.

What’s the benefit of the horizontal D-handle?

The horizontal D-handle provides a more ergonomic and comfortable grip during operation, reducing wrist and arm fatigue, especially during prolonged use.

Can the DW872 make miter cuts?

Yes, the adjustable fence allows the DW872 to make miter cuts up to 45 degrees to the left or right.

Why does my DW872 blade get dull so quickly?

Common reasons for premature blade dullness include cutting material that is too hard for the blade, improper feed pressure forcing the cut, using the wrong blade for the material e.g., aluminum with a ferrous blade, or hitting foreign objects embedded in the material.

Where should I get my DW872 blades sharpened?

You should send your carbide-tipped blades to a reputable professional sharpening service that specializes in carbide saw blades to ensure proper tooth geometry and grinding.

What is the warranty on the DEWALT DW872?

DEWALT typically offers a 3-year limited warranty on the DW872, along with 1 year of free service and a 90-day money-back guarantee. Always check current warranty details with DEWALT or your retailer.

Can I use abrasive wheels on the DEWALT DW872?

No, the DEWALT DW872 is specifically designed for use with carbide-tipped dry-cut blades. Using abrasive wheels on this machine is not recommended and can be dangerous, as it’s not designed for the stresses and heat abrasive wheels generate.

How does the DW872 handle heat-affected zones HAZ in metal?

Because the DW872 generates significantly less heat than abrasive saws, it creates a much smaller, or virtually non-existent, heat-affected zone HAZ on the cut material, which is critical for maintaining material integrity, especially for welding.

What are some essential accessories for the DW872?

Essential accessories include specialized blades for different materials non-ferrous, stainless steel, roller stands or material supports for long workpieces, and adequate personal protective equipment PPE like safety glasses, hearing protection, and gloves.

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