How To Flatten Aluminum Table Saw Top?

When the same table sawhas been loyal to youfor a really long time, the top of the table can become uneven. It’s natural to wonder how to fix the issue, especially how to flatten aluminum table saw top.

You can use a belt sander, a flap sanding disc, a sandblaster, or sandpaperto make the tabletop as flat as possible.

If you want to learn these methods in detail, make sure to read the entire article.

How To Flatten Aluminum Table Saw Top

How To Flatten Aluminum Table Saw Top?

You may have heard various things about flattening an aluminum table saw top. However, not all of them are effective. In addition, some methods may end up damaging your table saw instead of fixing the issue. So, let’s take a look at the most effective options you can use for your aluminum table saw top.

Belt Sander

One common solution people often go for is a belt sander or a disc grinder. If you are using the right way to sand your table saw top, there’s no reason why you shouldn’t get a perfect and flat table top.

What is the right way, and what is the wrong one? The first thing to do here is to use 100-grit sandpaper in the beginning. It makes the process easier and also more effective. Once you’re done flattening the coarse top with 100-grit sandpaper, move to finer ones like 150-grit or 200-grit.

You have to be patient with the procedure and careful too. For instance, if you hold the belt sander in one place for too long, you will scorch the table top instead of fixing it. There will be dust generated from the procedure, so make sure that you’re doing it in a well-ventilated area.

Last of all, take care of the heat your belt sander is generating. It’s important not only to keep yourself safe but also to protect the table saw from damage.

Flap Sanding Disc

By attaching a flap sanding disc to a power drill, you can easily get an effective metal shaping tool. As long as you stick to 100-grit sandpaper when using the tool for your table saw top, you can get surprisingly good results with this method.


You must be wondering why a powerful tool like the sandblaster is on this list. It may not be the most common tool people have in their homes, but it can be made available. What I am trying to say is that you can rent this tool from any rental shop.

Using 80-grit paper will get you the perfect finish you want. Nonetheless, if you think that the table saw top is more damaged than you anticipated, you can always utilize steel wool to smoothen the top before running the sandblaster over it.

As for uneven edges and other damages, try upgrading the paper to 100-grit, and all your issues will be resolved.

Ball Peen Hammer

If your table saw top is suffering from dents, the perfect way is to use a simple ball peen hammer. The method is exactly what you’re picturing in your mind. However, you will have to use some kind of padding on the aluminum table top before hammering your way out of unevenness.

In simpler words, use wood blocks on top of the dented area and use the hammer to flatten the area. You have to be careful about the force you are using. Otherwise, you will end up denting the tabletop in the opposite direction.


The simplest way to even your aluminum table top is to use sandpaper. Larger areas might be more tedious to flatten when you’re using sandpaper to manually flatten your table saw top. However, if the unevenness is in smaller areas, this can be the easiest and, most importantly, cheapest method of all.

Be careful when doing the task, and don’t rub too harshly. Protect yourself using appropriate safety gear to avoid injury. You can also check my article on how to fix an unsquare fence on a table saw if you are interested.

Safety Tips

  • When you’re fixing your uneven table saw top, always find a well-ventilated area to work in. It’s best to do this task outdoors.
  • Keep all flammable things at a safe distance when you’re dealing with rust.
  • Use your gloves, earplugs or earmuffs, goggles, and a mask when you’re using a power tool to fix the tabletop.
  • Make sure you are entirely comfortable with the tool you are using.
  • If you are not confident with doing the task, don’t do it. You can always get your table saw serviced at a tool shop. Or better yet, invest in a new and advanced table saw. You can check my article on the most quiet table saw if that’s what you are interested in.

Frequently Asked Question

FAQ Saw School

Can I use a metal file to flatten the aluminum table saw top?

A metal file will do an effective job when the table saw top is made of either wrought iron or steel. However, if its’ aluminum, it’s better not to go with this method. You may end up with permanent scratches on the table saw.

How do I make my table saw top smooth?

After you’re done making the table saw top even, you have to use a lubricant compound to make the surface smooth. For instance, paste wax is an effective option. When the table top is lubricated, the materials you are trying to cut will slide more effortlessly than before, resulting in cleaner cuts.

Final Words

I’ve tried to answer all your questions regarding how to flatten aluminum table saw top. All methods explained in this article are effective. However, they are not equally effective for all types of damages. For instance, for rust and other damages, you will want to use a belt sander or sandpaper. On the contrary, a hammer will be more effective on dents. If your table saw has both types of damage, you may have to combine multiple tools.


Hey there — I’m Elton Dunn, founder and Head Writer of sawschool. Though I personally think myself as a self-made entrepreneur, I am DIY woodworker. This blog is a humble attempt to help people choose the right saw from too many options. That’s why I stress on comparing various saw with one another than attempting to review each. Hope my reviews and comparisons benefit you. Have any feedback, questions, or recommendations? We would like to hear from you! Feel free you can anytime Contact with me.

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