This is an outdated version: see this post about stainless steel shims
Finally got around to figuring out how to bend my own steel shims for my table saw. I had read on some forum where many have had success using brass shim stock from their local hardware store. I thought that this was a brilliant idea but I thought that the brass stock would be too malleable and not allow for proper arbor alignment as the set screws would wear through fairly quickly.
I first created a jig where I could maximize material usage by allowing me to precisely cut stock to the final length of the shim, then to be able to cut the strips to the exact overall width of the shim so that it could be bent exactly to the dimensions needed. I think the pictures below are self explanatory.
https://goo.gl/photos/LeXKs8GUP7QhdbfG7
I am currently selling them on e-bay (Sold out). New Listing(Sold out). Yet another.
E-bay Stainless steel shim listing.
Or from my own website stainless or steel at a discount.
Place the sheet into the jig and score along the outer line formed by the outer aluminum bar.
Here is the score line made
Gently bend along the score line.
Bend a little bit back and forth
THe small segment separates
Turn the sheet 90 degrees and insert back into the jig and score along the outer edge of the inner aluminum bar
gently fold along the seam
the strip will break off
keep doing this until you are unable to break off anymore. Here the strip to break off is too small so we need to do something different
Place the thin strip in between two pieces of wood so as to be able to grip it well and bend off the short strip
fold it gently
here it has released
using the same jig to bend off the small strip, insert the hinge with a spacer to get an accurate bend (your setup might vary from this)
place the strip
clamp it down
bend the brass piano hinge segment over. You might want to lightly tap the hinge with a hammer to ensure the 90 is as good as you can get it
Then place the bent shim into a jig so you can bend the ears over. Carefuly place it so you get an equal amount of material sticking up from each end
cut a slit in the corner using a utility knife. Be careful to get into the corner as far as possible
slowly roll the utility knife over until.
use some solid piece of metal to help bend over the ear in a uniform manner
Fold over the other ear and repeat for the other end
Repeat for other side