How to make a carriage on a circular saw

The tenoning on the circular saw with his hands

Now you know how to make a machine from a manual circular saw, so let’s consider the tips of craftsmen:

  • Before you use an electric saw on the machine, check the saw disk with a square, because some unscrupulous manufacturers put the disk not exactly the floor at an angle of 90 degrees, which makes the saws appear beveled.
  • If you plan to use a table for storing tools on it, the size of the table top must be larger than 1 m2.
  • To create a machine, use strong and high-quality materials, because otherwise it will not last long.
  • The table can be supplemented, for example, craftsmen sometimes manage to attach a special vacuum cleaner or a wedging knife with protection for the discs, so that the remains from cutting wood and shavings do not fly on all sides.
  • You should choose in advance a place for mounting the table, and also make sure that the floor, where the table will stand, is perfectly flat.
  • If you have the skills and desire, you can make a folding countertop, but here you will need to spend more effort, time and materials.
  • If the table vibrates or wobbles while working, you should adjust the height of the legs with rubber.

As the circular saw is an electrical device, it is worth working with it by professionals. The transfer of the switch to another place should also be entrusted only to specialists.

How to choose a saw

Of course, when there is a work experience, and you do not want to invest in the purchase of a lot of money, you can make such a machine by yourself

When buying a saw for it, take into account

  • Buy a machine with a protector that must not only cover the platter in peace, but also during operation.
  • Choose the weight and size of the device taking into account your own goals. With volumetric interaction will be more difficult, you will get tired after half an hour of activity.
  • Take into account the convenience of the saw, so you can work comfortably with it.
  • Take into account the diameter of the saw blade (no more than the 0.2 m mark). Examine the dimensions of the cut. when cutting volumetric parts you need to choose a larger size.
  • Make sure the rotary block and bed are of good quality.

Regardless of whether you decided to buy the factory version or to build your own saw, it should be easy to work with it, and the result should be of high quality.

Step by step instruction

So, the construction details and the necessary tools are selected, you can proceed to the assembly and subsequent installation of the homemade carriage.

Fixing the aluminum profiles

Since the carriage will be “running on the sawing table”, the first thing to do is to make the guide grooves. For this take two U-shaped profiles, roughly equal to the length of the table. Adjust the dimensions with an angle grinder.

At an equal distance from the position of the cutting disc of the circular saw, draw two lines parallel to it. Then, using a hand router, you saw out the U-shaped holes on them, blow the chips out of them and use glue to fix the profiled pipes in them. After the glue has dried. the grooves are ready.

Read more:  How To Choose A Circular Saw For Your Home

Making the carriage base

Further a mobile base of the crosscutting carriage is designed. To do so, two strips are taken that fit into the U-slot loosely according to their thickness. But there is one moment. the carriage will have to “glide” freely on the table, and for this purpose it is raised by 2-3 mm above the table. To do this, nuts of equal thickness are placed in the profile slots at equal distances, and then the guide rails are placed on them.

Then glue is applied to them, which fixes the plywood base strip. To hold it more tightly, you can fix the sides of locks.

When the resin dries, the nuts are removed from the profile grooves and the master checks whether the carriage walks freely on them. After that, for the convenience of further use, the carriage is cut on the sides along the profile of the table.

Mounting the walls

The base is now ready and the thrust walls are then set in place. To do this, two wooden blocks are taken: one of them is fixed firmly, with self-tapping screws, along the edge nearest to the master so that it is strictly perpendicular to the saw’s cutting edge; the second is fixed along the upper edge, but only on one side. This is so the craftsman can align this wall exactly parallel to the lower wall. Carry out the test-cutting using a square.

After the walls are aligned, a test cut is made. It has two purposes. it is used for sawing holes in the walls and base of the carriage, and then measuring the sawed workpiece to check whether the right angle of cut is correct.

Important. The height of the walls must be high enough so that the cutting edge does not penetrate more than half of them, otherwise the carriage could break during operation. an unreasonable risk when working with a circular saw.

Making a combination square for cutting at an angle

So, a normal carriage with a straight broach is ready, but what if the craftsman needs to saw something at a different inclination, such as 60, 40 or 30 degrees? For such operations an additional constructional element called a “combined square” is needed.

The name is not accidentally taken in quotes. the fact is that the basis of the workpiece is really a square wooden platform. It is sawn out so that it fits freely between the stops of the main carriage and one of its sides is fixed at the bottom wall.

After that, the workpiece cutted, cutting out of it fragments at the right angles. the resulting bevels and will be the guide that lays the part that needs to be sawed at this angle.

“Square” after manufacturing is rigidly (with glue or self-tapping screws) mounted on the carriage. Another, more advanced variant. using a router rounded slots are sawed in the square and the carriage base which allow the square to move along the base on a movable clamp. It is made from a screw, a nut, and two metal washers.

Detailed video of how to make the end mill carriage described above:

make, carriage, circular

Bearings in the cutter carriage

There are two types of bearings in the installation of the guide:

Cylindrical roller bearings and rollers have two significant disadvantages compared to rail cars: They have a low load bearing capacity and a high backlash. In order to maintain the weight, the studding carriage is mounted on the trimmer’s guide line by several shafts.

  • Not designed to withstand high loads.
  • High pressure build-up due to low service life. Need for periodic shaft replacement due to groove formation.
  • Sawdust and sticky dust clog the slots.
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Bearings are made of non-hard metals, such as caprolon, to ensure sliding on the surface. If all tolerances are respected, the load capacity and precision of the plain bearing are good enough. Nevertheless, sawdust and dirt can not harm the unit. But this only applies to bronze parts that are quality machined.

Over time there is wear and tear on the product that requires periodic adjustments to get rid of gaps. As a rule, more affordable bearings are used for manufacturing with your own hands.

A simple circular saw carriage with your own hands

Hello, dear readers and do-it-yourselfers!Some of you work on a circular saw quite often and sometimes have the task of cutting very large workpieces, such as shelf panels and other furniture designs.

In this article, Kate Brown, author of the YouTube channel “Rag ‘n’ Bone Brown,” will give you detailed instructions for making such a custom fixture as a panel sled, or carriage for cutting large panels.

This project is very simple to make, and can be repeated for a few minutes.

Materials Sheet wood, chipboard, wooden beam, wood screws and washers.

make, carriage, circular

All that the craftsman has in his arsenal for cutting wide panels is a traditional angle gauge, which, in particular, he uses in a peculiar way for this purpose.

However, in the author’s opinion, the miter gauge is not very accurate, since it does not sit tightly enough in the groove and therefore has a little “backlash” from side to side. As a consequence, the cuts are not always neat and accurate.


As you know, the angle can be rotated at different angles during work. Such mobility has a downside. to make a cut at a perfectly right angle, you have to use a trivial angle.

So, the author takes a panel of laminated chipboard (the door from an old kitchen cabinet), a thick oak beam (from which the guide will be made) and a scrap of furniture plywood board for the cross support.

Чаша на циркулярной пиле. / A circular saw make a bowl.

Thanks to the author for a simple but useful attachment for the circular saw!Good mood, good luck and interesting ideas!

make, carriage, circular

What to consider when working

Attention! Safety precautions must be followed. The work is best carried out not in the living space, but, for example, in the yard or garage.

Useful Functions

What else would be useful to have on hand for the handyman:

  • Clearing knife. preserves the integrity of the disc, prevents it from getting pinched.
  • Dust collector to remove sawdust in the course of work in a special container. This vacuum cleaner cleans both the cutting area itself and the air in the room. The tool is connected to the saw through an adapter.
  • Lift-machine (or just lift-machine) for lifting the cutter to the desired height.
  • The pointer in the body of the saw helps to make more precise cuts.
  • Lighting: the presence of lighting in the circular saw makes it possible to use it in any room, even quite dark.
  • Rubber handles so that the sawing tool sits securely in the hand.
make, carriage, circular

The circular unit and the skid to it can be of different appearance and purpose. The design of the tenoning guide has a complicated scheme of making and is not available to every craftsman. However, the described wood carriage instruction is clear and can be repeated quite quickly and without specific tools.

The process of making a trim carriage

Under the main sole of the manual circular saw it is necessary to make a superimposed one. For this purpose, the plywood is cut to the size of the regular one, with small tolerances in the larger side.

Then on it around the perimeter glued laths with longitudinal cuts and ends at 45 ° to get a frame.

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The plywood is positioned in it like a veneer. It is necessary that these sides protrude flush with the standard sole of the circular saw.

On the saw blade side the frame is glued and then screwed on. It will hold the overlay sole on the regular.

On the back side, this is performed by 2 self-tapping screws with washers. After the slip-on sole is in place, switch on the circular saw and cut through.

A piece of Plexiglas strip is cut to the width of the sliding sole. On the sides, the drawer rails are glued to it with double-sided adhesive tape. The length of the plexiglass workpiece should be equal to the size of the rails when open. Next, the parts are screwed together with short self-tapping screws.

Then the removable sole is glued to the guides. It must be screwed to their extension bars.

A circular saw is mounted on the resulting guide and carriage. Then it must be turned on and the disk must be lowered to make a cut in the Plexiglas along the entire length of the extension.

On the reverse side of the guide, a stop is screwed from a bar strictly perpendicular to the saw blade. Its width should exceed the disc protrusion depth. It is then sawn through as well.

The bar underneath is now used as a parallel stop. If the side surface of the board is straight, then with this attachment the circular saw will saw it off strictly at right angles along its length.

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In this video I will show all the improvements on my saw carriage. As I said before, after the heating season is over, due to increased humidity most of the sliders on the carriages can’t move freely in the grooves of the circular saw table. This problem was fixed, but I suspect that by the end of the year it will be gone. It will be back for the heating season )) There is a solution, which I will tell you about soon.

In this video I will also tell you about simple but very useful templates for setting all the common angles when working with a circular saw. Patterns were made for me by Seryoga Petreev on CNC machine tool. His channel.

I’ll show you one more carriage, which is a logical continuation of its older sister. This whole set of fixtures was created for cutting elements of complex segments for turning products. In the next video I will show everything in work and on different examples. There will be a lot of complications, but questions like I did it now you will not have))

Pros and cons of the homemade carriage

The advantage is that you can do for relatively little or even no cost whatsoever what a particular craftsman needs.

The disadvantage is that the simplest homemade options can not provide the ease and accuracy of movement, which are the factory products with linear guides on plain bearings.

It turns out that the carriage is a useful tool, especially in the carpentry workshop, when high precision in sawing materials and in addition it can be made with your own hands and inexpensive. Remember, the strength, durability and quality of work of the homemade carriage for the circular saw depends on the quality of the assembly and selected materials.