Proxxon Saw Modifications
Tony: I just completed a mod for the guide system on my Proxxon chop saw. As you know this saw was designed for micro models so the measured part falls to the right of the blade and is not supported. This is backwards for most of us who like to clamp our measured part in the vise and have the extra fall off the right side of the blade.
Here is how I modified my Proxxon so it cuts like a traditional chop saw. The steel block that holds the gauge/rod is held in place with two M5.0.8 15mm cap screws. Replace them with cap screws at least 1/2" longer. Fabricate a riser block 1/2" high and attach it under the original block. Reverse the gauge/rod. The gauge now rides flush on top of the clamping vise. I tightened mine so it will not flop on the rod. Check for squareness of the gauge/rod with the bottom of the vise platform where the objects to be cut will rest.
The black metal guide now floats on top of the jaws ready to gauge the length of blanks or brass tubes and clamp them in place with precision in relation to the blade. However most items are too small to fully engage the blade guide. The final mod is to attach (epoxy) a small vertical rod to the blade guide that is smaller than the smallest item you will be measuring and clamping in the vise. I attached a small rod to the center of the blade guide and raised this small rod about 1/16" off the bottom of the vise so it floats without rubbing. Make sure to attach this to the blade with the vise in the closed position to support the small rod. Now brass tubes can drop between the jaws and this guide post will engage them precisely as well as larger objects like pen blanks.
The easy way to use this set up, without using a scale for each cut, is to use a reference gauge (tube or blank). Carefully lower the blade and insert the reference gauge against the left edge inside tooth of the blade and slide the guide/rod up against the left end of the gauge and lock the guide/rod in position. This works best for old eyes that have a hard time reading a precise scale to the nearest 64th of an inch or mm.
I have photos of this mod attached below that illustrate these steps.