Hico miter saw stand end caps

I bought the HICO UWC4000 miter saw stand thinking it would be a great, cheap stand to use my Hitachi C10FS dual bevel sliding compound miter saw (oldie but goodie!) on the jobsite. It worked reasonably well, and at $70, who can complain? The nearest comparable stands are $150+.

HICO UWC4000

The weak link in this stand is the way the attach the material supports–the foundation of any decent miter stand. The chose to make a load-bearing piece out of cheap nylon plastic. Mine broke within a week! Now the supports won’t sit flat. Luckily, this is an easy fix. I drafted the part in SketchUp and produced a flat pattern. I ordered some flat aluminum bar stock. I chose 6061 due to its excellent machinability, light weight, and affordable price tag. Here are specs on 6061 aluminum:

Ultimate Tensile Strength, psi 45,000
Yield Strength, psi 40,000
Brinell Hardness 95
Rockwell Hardness B60
Chemistry Aluminum (Al) 95.8 – 98.6%
Chromium (Cr) 0.04 – 0.35%
Copper (Cu) 0.15 – 0.40%
Iron (Fe) 0.70%
Magnesium (Mg) 0.8 – 1.2%
Manganese (Mn) 0.15% max
Silicon (Si) 0.4 – 0.8%
Zinc (Zn) 0.25% 

As soon as it comes in, I’ll mill the piece and post pics. If you’re having the same issue with your UWC4000, here are plans to make your own or have someone make them for you!  The part is a mirror image of itself on both sides, so the pattern works for right or left brackets.

Hico endcap pattern

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