You know that feeling when you buy a tool and it just clicks? That’s usually the first five minutes with the DeWalt DW788 20-inch variable speed scroll saw. Honestly, it’s a bit of a legend in the woodworking world, which is weird because scroll saws aren't exactly the rockstars of the shop. But this yellow beast has a following that borders on a cult.
Walk into any serious hobbyist’s garage and you’ll likely see it sitting there. It isn't the cheapest. It certainly isn't the newest design on the market. In fact, DeWalt hasn't changed much about this machine in years. Why would they? When you get the arm design right, you stop messing with it.
The DeWalt DW788 20-inch variable speed scroll saw solves the one thing that ruins every scrolling project: vibration. If your saw is shaking, your cut is garbage. Period. Most entry-level saws use a simple pivot point that makes the blade move in a slight arc, which chatters against the wood. DeWalt uses a double parallel-link arm. It sounds fancy, but it basically just means the blade stays almost perfectly vertical. It reduces the "thump-thump-thump" that makes your fingers go numb after twenty minutes of intricate fretwork.
The Reality of the Double Parallel-Link Arm
Most people don't realize that the magic is in the back of the saw. The design keeps the pivot points at the front of the arm, near the blade, rather than way in the back. This makes the movement shorter and tighter. It’s quiet. So quiet you can actually listen to a podcast or have a conversation while you’re cutting out a 3D puzzle or a name sign.
There’s a catch, though. Some users, like the legendary scroller Steve Good, have noted over the years that while the DeWalt is a workhorse, the quality control can occasionally fluctuate depending on where the unit was manufactured. You’ve gotta check the table for flatness the second it comes out of the box. Most are dead flat, but if yours has a dip, send it back. A warped table on a scroll saw is like a flat tire on a Ferrari—it’s just not going to work.
Why 20 Inches Matters More Than You Think
You might think sixteen inches is enough. It usually is, until it isn't. That extra four inches of throat depth on the DeWalt DW788 20-inch variable speed scroll saw is the difference between being able to rotate a large piece of plywood and hitting the back of the saw frame.
Imagine you’re working on a large clock face or a detailed map. You’re halfway through a delicate turn and—clunk—the wood hits the arm. Now you’re stuck. You have to back out the blade, which is how blades break and wood gets scarred. Twenty inches is the "Goldilocks" zone. It's big enough for professional-sized projects but doesn't take up the massive footprint of a 30-inch industrial saw.
Speed Control and the Front-Facing Layout
Everything is on the front. This seems like a small detail. It isn't. On older or cheaper saws, you have to reach over the moving arm to find the tension lever or the power switch. That’s just bad design. On the DW788, the tensioning lever, the power switch, and the variable speed dial are all right there at your fingertips.
The speed range goes from 400 to 1,750 strokes per minute. If you’re cutting thick maple, you crank it up. If you’re doing paper-thin veneers or even soft metals like brass, you dial it way down to keep from burning the material. It’s smooth. No notches, no presets. Just a dial that feels like the volume knob on a high-end stereo.
The Tool-Free Blade Change Myth
DeWalt claims "tool-free" blade changes. Is it? Yeah, mostly. The clamps are easy to tighten by hand. But let’s be real: after a few hours of work, your fingers get tired. A lot of pros end up buying aftermarket "Easy-Hone" or "Pegas" blade chucks anyway.
The stock clamps are good, but they can be finicky with very fine blades, like a #2/0. If you don't get the tension just right, the blade slips out with a loud ping. It’s startling. It’ll make you jump. But once you develop the "feel" for the finger-tighten tension, it’s one of the fastest systems out there for "hole hopping"—that's when you're doing internal cuts and have to constantly unclamp and re-thread the blade through a new pilot hole.
Maintenance and the "DeWalt Knock"
Let's talk about the elephant in the room. Some units develop what scrollers call the "DeWalt Knock" after a few hundred hours. It’s a rhythmic clicking sound. It usually means the bearings in the arm need a little grease or a shim. It's not a dealbreaker, but it’s something to watch for.
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Maintaining the DeWalt DW788 20-inch variable speed scroll saw isn't hard, but you can't ignore it. You need to blow the sawdust out of the motor housing regularly. Sawdust is the silent killer of variable speed controllers. If the dust builds up, the electronics overheat, and suddenly your variable speed saw becomes a "one-speed-only" saw.
- Check the tension: Don't over-tighten. The blade should "ping" like a guitar string, not "thud" like a wet noodle.
- Table Care: Use a bit of paste wax on the cast-iron table. It keeps the wood sliding like it’s on ice and prevents rust if your shop gets humid.
- Blade Choice: Don't use the cheap blades from the big-box stores. Get some Flying Dutchman or Pegas blades. A great saw with a bad blade is just a vibrating paperweight.
Comparing the Competition
If you're looking at the DW788, you're probably also looking at the Delta 40-694 or the high-end Excalibur. The Delta is basically a clone of the DeWalt. It’s often cheaper, but the support isn't always as robust. The Excalibur (and its various rebrands like Pegas or Jet) has a tilting head instead of a tilting table.
That’s a big deal. On the DeWalt, if you want to make an angled cut, you tilt the table. This means you’re fighting gravity, trying to keep your wood from sliding down the incline while you cut. On a tilting-head saw, the table stays flat and the saw arm moves. Is the DeWalt worse because of this? For 90% of people, no. Unless you’re doing massive amounts of marquetry or inlay, the tilting table is perfectly fine. Plus, the DeWalt is usually hundreds of dollars cheaper than the tilting-head models.
Dust Management: The Weak Link
If there’s one thing to complain about, it’s the dust blower. It’s a little plastic tube that’s supposed to puff air on your cut line so you can see where you're going. It’s... okay. It’s not great. It sort of wheezes.
Most serious users end up rigging a small aquarium pump or a dedicated shop-vac attachment to the arm. If you can't see your line, you can't cut accurately. The stock blower gets the job done for simple shapes, but for fine portrait scrolling, you'll want a better solution.
Is it worth the investment?
Price is always a factor. You can find scroll saws for $150. The DeWalt DW788 usually sits somewhere between $450 and $600 depending on if the stand and light are included. That’s a lot of money for a hobby tool.
But here is the thing: cheap saws are frustrating. They vibrate so much they walk across the workbench. They're loud. They break blades. The DeWalt is a "buy once, cry once" tool. It holds its value incredibly well. If you buy one today and decide in two years that scrolling isn't for you, you can sell it on the used market for 70% of what you paid. You can't do that with a budget saw.
Setting Up Your Workspace
When you get yours, don't just bolt it to a flimsy plywood table. The DW788 is heavy—about 56 pounds. It needs a solid base. If you get the official DeWalt stand, make sure you adjust the legs so there’s no wobble.
Lighting is the other big one. The optional DeWalt light is fine, but a dedicated LED goose-neck lamp that you can position right over the blade is better. You need to see the "kerf"—the tiny path the blade leaves behind—to stay on track.
Real-World Performance
I've seen this saw handle everything from 2-inch thick oak to delicate 1/8-inch Baltic birch plywood. It doesn't bog down. The 1.3-amp motor is surprisingly punchy. When you’re pushing a thick piece of hardwood through, you can hear the motor compensate, maintaining that constant stroke speed. That’s the "variable speed" part of the DeWalt DW788 20-inch variable speed scroll saw really earning its keep.
Honestly, the best part of owning this saw is the community. Because so many people own it, if you ever have a problem, there are a thousand YouTube videos and forum posts showing you exactly how to fix it. You aren't just buying a tool; you're buying into an ecosystem of patterns, modifications, and expert advice.
Actionable Steps for New Owners
If you've just pulled the trigger on a DW788 or you're about to, here is exactly what you should do to get the most out of it.
First, throw away the blades that come in the box. They are usually mediocre. Order a "variety pack" of high-quality reverse-tooth blades. Reverse teeth have a few teeth pointing upward at the bottom, which prevents the wood from splintering on the underside. It makes for much less sanding later.
Second, check your blade alignment. Square the blade to the table using a small machinist square. Don't trust the built-in scale on the front of the saw. It’s a sticker, and it can be off by a degree or two. If you're cutting pieces that need to fit together, like a box or an inlay, that one degree will ruin your project.
Third, consider the foot switch. DeWalt sells one, but any deadman-style foot pedal works. It allows you to keep both hands on the wood at all times. You start and stop the saw with your foot. It’s safer, more efficient, and honestly, it just makes you feel like a pro.
Finally, don't overthink the tension. Newbies always snap blades because they over-tighten them. Tighten it until the blade doesn't bow when you push the wood against it, and then stop. It’s a feel thing. You’ll get it after the first three or four breaks.
The DeWalt DW788 remains the benchmark for a reason. It’s the bridge between the "cheap toys" and the "industrial monsters." It’s reliable, quiet, and capable of incredibly fine work. Whether you’re making Christmas ornaments for the family or selling high-end fretwork at craft fairs, this saw is more than enough machine for the job.
Check your table for flatness, get yourself some decent blades, and start making sawdust. You won't regret it.