How to make a mini circular saw with your own hands

How to make a circular saw out of a circular saw with your own hands

Before building a machine, it is important to decide on its purpose. In order to cut firewood and perform simple sawing, it is enough to have a securely fixed table with a slot for the saws. But it’s hard to call such a machine safe or functional.

To do more work, it is worth making a circular saw equipped with a coordinate table. It should have guides. This will help to change the degree. At the same time it is worth providing the possibility of switching speeds and changing discs.

You can make a circular saw from a variety of fixtures. Almost every man has an angle grinder in the range of tools. It is often used in the home. To make a stationary installation, you need to use a workbench or a special table. The tool should be fixed from below.

So, how to make a circular saw? To do this, you need to do the following:

  • Stretch a metal band clamp over the tool. Its coupler must be placed at the bottom.
  • Fold the metal strip in half and secure it in the area of the holes.
  • Make holes in the gearbox of the angle grinder.
  • Attach an axle handle.

Please note! Handle can be made of metal rod or pipe. The workpiece must resemble a staple in shape.

The tool can be made from an angle grinder

Design features

Structurally, the homemade sawing table looks quite simple. The machine consists of a supporting frame for mounting of a motor, a transmission unit and a working table with a slot for a cutting disk. The design is equipped with stops to guide the workpiece and a protective screen that prevents shavings, as well as increasing the safety of work.

Obligatory requirements for the sawing table:

  • Rigid, stable construction;
  • The smooth surface of the tabletop;
  • Safe mounting of the blade;
  • fencing to protect the operator of the machine (table);
  • easy access to the control unit (start and stop buttons).

Equipment must be mounted on a frame supported on legs instead of solid sheet metal. This makes the saw table more comfortable to work with, although it makes it less stable. The frame can be made of metal or it can be reinforced with metal parts to increase resistance. Not only is the blade guard secure, but the disc is also secured on the underside (inside) of the frame. Additional requirements depend on the nature of the work. auxiliary elements help to process parts more accurately, cut longer boards as well as thicker logs.

By making a saw table with your own hands you can get a number of advantages, from cost reduction to the possibility to change the design as required by the craftsman. If desired, you can replace some of the parts more favorable in cost, to use materials left over from the repair or construction. The only disadvantage of the circular saw, independently mounted on the machine, is a decrease in the accuracy of positioning of the workpieces. But this point still largely depends on the skill of the performer himself.

Rigid, stable construction

Smooth surface of the table top

Securely fastening the circular saw blade

Fences to protect the operator of the machine (table)

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Design options

Now we need to know a little bit about the possible structural solutions.

With asynchronous electric motor

To adapt an angle grinder as a drive

Conclusion. For the non-professional craftsman, the most optimal variant for making a stationary circular saw should be considered the use of a portable circular saw as a drive.

make, mini, circular, your

I make a fixture for the guide of the circular saw

In order to be able to cut wood as well as possible, a stationary saw has to be fitted with a guide. It will be a bar for the entire length of the tabletop, set parallel to the blade of the saw.

For its attachment I prepare 2 pieces of wood and 2 strips of plywood, which I attach on the edges of the table perpendicular to the blade of the saw. Then I measure the table top and trim the edges, so that the guide would be parallel to the saw blade when moving.

Compact table machine

Above mentioned how to assemble a manual circular saw. Now we will tell you how to turn this device into a stationary one. This process involves making the U-shaped base from a pipe and installing the cross-arm. The lower ends of the structure must bend horizontally in the sawing direction. They are attached to the table with bolts. Stability is ensured by additional supports.

Arm mobility is provided by sawing the horizontal segment into two identical parts, which are fixed between each other with clamps. The saw blade is attached to the vertical element of the bed with clamps.

Stationary installation

The machine, similar to the factory models, needs a competent attitude in the assembly process, so you need to take care of all the details in advance. The table version of the “circular saw” differs from the stationary version only in the height of the bed, which is determined by the specifics of work and the size of future workpieces. One-time processing can also be done with an ordinary table saw, which after the work can be easily stowed in a pantry or shed. But the master, who constantly deals with wood, will need a stationary installation. Consequently, he needs to make a table for a circular saw with his own hands.

Circular machine has the following advantages:

From the foregoing it can be concluded that self-made circular saws have a clear and simple design, and the drawings that can be found on the World Wide Web, will greatly simplify the process of assembling equipment. Before self-made “circular saw” should be considered separately all the necessary elements in order to understand the nuances of functioning and installation of homemade equipment.

“A circular saw from a circular saw.

Among self-taught carpenters, it is believed that the transformation of a manual circular saw into a machine tool is the easiest method of obtaining “three birds” at once, namely:

  • high quality of cut, guaranteed by high rotation speed of the saw;
  • the shaft mounted in the collector motor on bearings, which withstands with honour the radial load;
  • ideal (cantilever) mounting of the disk, it gives the possibility to change the cutting tool relatively quickly, so there is no need to disassemble the circular saw.

The main advantage of making such a machine is a “native” motor, which guarantees maximum performance due to the ideal torque, optimal revolutions. Other advantages of this solution:

  • Relatively easy-to-use locking system that lets you remove the saw quickly in the event of a major need.
  • Powerful motor that enables long working hours because of its ability to withstand considerable loads.
  • A normal thermal environment, guaranteed by the forced ventilation of this hand tool.
  • Possibility to obtain sufficient cutting depth by using discs of big diameter. 60-75 mm is a value that gives a good chance to make high-quality blanks for different products manufactured at home.

Wall and table top

Modification of a hand saw into a circular machine starts with making a table (or a body-box), on the back side of which the hand-held power tool will then be attached in such a way that part of the cutting edge protrudes over the surface of the table top.

Form and size of the table choose, focusing on the size of the future lumber. If you plan to make small billets, then a length of 1500 mm and a width of 600-700 mm will suffice. For the manufacture of the bed of the circular saw is suitable steel angle, which has a shelf width equal to 25-30 mm. On the top and bottom of the structure reinforced struts made from the same angle or rebar. This variant is optimal to ensure maximum rigidity to the frame of the machine.

For the countertop often choose laminated chipboard or OSB, some masters stop at plywood, the thickness of this material. 15-20 mm, but you can take a thinner material, and then join together 2 sheets. The elements that make up the worktop do not need to be of the same size, they must be symmetrically positioned in relation to the bed. The main thing is that the construction is not at risk of overturning.

In the tabletop make a notch, designed for extending the disk. The part of the table surface that will be adjacent to the cutting instrument is often covered with tin, metal sheet (aluminum, steel), textolite or plastic. This solution makes it possible to maximally facilitate the movement of the wooden lumber.

Modification of the saw control

Such operations can be performed only in one case: if the tool has expired warranty period. For ease of control of the circular saw, the contacts of the button and the knob (lever) are led to an external electric switch, which is mounted on the body in a convenient location, but where completely exclude accidental pressings.

If the owner foresees a possibility of removing a hand-held tool from time to time in the future, the contacts are fixed with a tape or clamp. In this case the circular saw cord is plugged in the carrier equipped with the on/off button.

Guide ruler

It is essential for accurately cutting material of different widths, so this ruler (stop) must be able to move parallel to the cutting edge. Such element is also made of steel angle. Make slots in the tabletop, in which they fix the ends of the guide rail with screws.

A simpler option is a pine board. Its width is 40 mm, its length is 200 mm more than that of the table. First, nuts are pressed into the lower part of the protruding edges, and L-shaped hooks are fixed with screws. After installing the board on the tabletop of the circular grinder, they are tightened with screws, thanks to them, the hooks are raised and securely fasten the ruler. It is just as easy to move it to any place.

Circular saw from an angle grinder

This variant of making the machine is more popular, as a rare owner, who likes to do everything with his own hands, does not have, or in the near future is not going to buy, an angle grinder. The first of the steps of making a stationary saw unit is also to make a special table to mount the angle grinder.

In this case, the process becomes more complicated, because the main difficulty is thinking about how to attach the angle grinder to the bed: how to make a sliding stop and an axial handle. There is, however, a ready-made solution that enables a solid connection.

  • To make the sliding stop take two pieces of steel angle. They are fastened on both sides of the saw blade. Then they are connected by a cross tie (bolts and nuts). To ensure the necessary clearance, washers are used.
  • Beforehand a metal band clamp is stretched on the tool, the screw tie of it must be at the bottom. A metal strip, folded in half, is attached to the holes designed for the sliding stop.
  • In the gearbox of the angle grinder, several holes are made for the bolts: first the body is disassembled, then the points for drilling are marked. They will be used to fasten the axial handle. This element is made from a bar or metal pipe. The handles are shaped like a staple. At the ends, where the fastenings to the gearbox are located, holes are drilled.
  • They make a bar, obliged to regulate the depth of sawing. It is made from a piece of metal bar. On one side of it form a hinge, then it is slightly riveted, drill a hole designed for a thrust bolt. On the other end you cut the thread, screw on one strong nut first, and then the second one, when the construction is assembled. The depth of cut will be adjusted by tightening or loosening them.

Not too complicated steps will make it possible to get a full-fledged circular saw for cutting different materials. Do the same with the drill, which can to some extent replace the angle grinder. To avoid potential mistakes, it is better to use the drawings, which can be found on the Internet if you want.

Disc speed and safety

Unless the toothed blade rotates at high speed, the quality of the cut cannot be guaranteed. However, for homemade equipment operated in the conditions of the home workshop, no less important is safety during work.

It is necessary to provide for safety devices with which industrial models are traditionally equipped. The opinion that you can do without such protection at home does not stand up to criticism.

Safety rules are “written with blood. One awkward movement is enough to get on a surgeon’s table. That’s why you should pay the utmost attention to safety.

How to make a good smokehouse from a washing machine drum

The cherry on the cake in our question is the smoker. Smoked meat, lard and fish. what could be better to the table?? If you have in the shed or garage dumped tank from a car with vertical loading. consider it a deal in the bag. In the bottom of the tank you need to cut a hole for the firebox, inside weld mounts for hanging food. All that remains is to place the tank on the hearth, hang fish or lard, cover the tank with a lid on top and light the sawdust.

The products need to be smoked for several hours until they are ready

It is important that the fuel under the smokehouse smolders, not burns. The best place to put such appliance is far from your house

We hope we’ve convinced you that you shouldn’t scrap your old washing machine

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How to make a good smoker out of a washing machine drum

The cherry on the cake in our question is the smoker. Fragrant smoked meat, lard and fish. what could be better for the table? If you have a tank from a car with a vertical load in the barn or garage. consider it done. In the bottom of the tank is necessary to cut a hole for the firebox, inside weld mounts for hanging products. All that remains is to set the tank on the hearth, hang fish or lard, cover the top of the tank with a lid and light the sawdust.

You need to smoke food for a few hours until it’s ready

It is important that the fuel under the smoker smolders, not burns. Such appliance is better to be placed away from home

We hope we have convinced you that you should not scrap your old washing machine

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Stability of the table

The table for the circular saw with his own hands must be strong, reliable in operation, extremely stable. All functional units must be able to withstand severe mechanical stress, because powerful vibrations are often encountered during operation.

If for the master multidirectional pulses are not dangerous, then the quality of the cut can be very adversely affected: rough traces of teeth are formed on the cut, it becomes difficult to maintain the required dimensions of the finished parts.

About safety

Woodworking machines are equipment that creates increased danger. There is no space in a popular article to recite the contents of the TU and TSA volumes, and the DIYer is responsible for himself. So let’s briefly show “from the opposite”: what the circular machine should not be to work on it without possibility of injury and mutilation. An example of a “work of art” which is in breach of all the indispensable rules for more or less safe construction of sawing and hacking machines is shown in Fig. (electrical part is a separate topic).

Example of a faulty and dangerous circular sawing and boring machine

  • A. saw blade without guard. This is a common malady of almost all home-made circular saws. Like, keep your fingers away from the saw, use the workpiece pusher, and that’s it OK. So, for your information. now in internet you can easily come across on saw blade, made by methods of powder metallurgy. When it hits a nail, it breaks into small sharp splinters very readily.
  • B. disc protrusion is clearly more than 1/3 of the diameter. “Bites” of the jerky workpiece in your hands, shaggy step cutting. unavoidable. Injuries at work are more than likely.
  • C. the power train is also not covered by the jacket.
  • D, D. a table made of dissimilar low-quality materials. Transverse misalignment of the workpiece and “binding” of the saw with all sorts of bad follow-up is also quite probable.

What kind of discs to take

Circular saw blade is the most important part of a circular saw, the working organ it is made for. All machine construction is also linked to it, so we need to decide beforehand which discs we are going to use in our work and how to choose the right one online according to designation marks on it or in the description.

Types and naming systems of circular saw blades

The most common are 2 designation systems. According to the first system (n=1), the diameter of the cage should be 24 mm. A pos. 1 in fig.) are marked consecutively:

  • Disc diameter by tooth tips, mm;
  • cutting width, mm;
  • diameter of mounting hole, mm. Typical (by default) tolerance of 0,05 mm is not specified;
  • Non-typical tolerance on fit (it is possible);
  • number of teeth;
  • The letter T or pictogram shows the presence of carbide tips on the teeth;
  • speed. operational (nominal) simply in numbers, the maximum allowable with the prefix max.

For the second system, it is obligatory to indicate the size of the disk, in numbers separated by hyphens: diameter at the tooth flanks, number of teeth, fit diameter (the default tolerance is the same). E.g., 190-36-30 in item. B pos. 2 means a disk with 190 mm diameter (on the tops of the teeth would be 200) with 36 teeth for a fit of 30 mm. A separate speed is given, but here it is the maximum default; the working speed is 10% less. Other parameters are stated either by symbols (pos. B pos. 2) or textually. Minimum rotational speed at which the proper cutting quality is still ensured, for certified discs with stabilizing slots (item. 1, 2, 4, 5) 50% less than the working speed, and for solid discs 25% less.

Discs of quite good quality “outside the system” are available for sale (pos. 3-5). But in all cases just “on a tree” (pos. 2-4) denotes the corresponding specifications of the business wood, plywood, chipboard, laminate, etc. Good enough wood materials. It is dangerous to saw with such a disc when the wood is not matured. it can jam and fly off. For cutting wildwood there are special discs marked Forest, pos. 5), Wildwood, Timber, Log, etc.п. These designations are used in stationary pendulum saws, circular saws, etc., but they are not used in all applications. equipment for sawing raw wood.

Note: if you are going to saw metal with a circular saw, be careful. blades for steel and aluminum are not interchangeable. There are also universal saw blades for cutting any kind of material, but they work roughly and are not very good at cutting. Sawing with “universal” laminate, Laminated chipboard, etc. Laminated materials are not allowed. the coating will peel off.

Finally, there are a lot of unmarked circular saw blades for sale, pos. 6 in fig. In general, they cut, but you have to be careful with them: the linear rotation speed of such a disk is better not to give more than 40 m/sec. To get the rotation speed from it (to calculate the gear), measure the diameter of the disk at the tooth base D (in mm) and calculate its operating speed as 60(40 000/(3,1415xD)). e.g., The operating speed of the “muddy” disc at 200 mm will get 3815 rpm; it is better to take 3500.

The materials used to make the machine are:

The process of making a circular machine is shown at

Also we need the axle, housing bearings, a couple of pulleys and a belt.

On one end of the axle is installed pulley, and on the other end is a flange to mount the discs from the circular saws.

the housing bearings are bolted to the frame.

From a piece of sheet steel, make a pad mount for the motor.

We make a table top of sheet steel, it is better to take a thicker metal, so it does not bend and do not affect the process of cutting.

Under the sheet of steel the author has made rests from pieces of pipe, the sheet should be raised above the axle and bearings.

It goes without saying that the table top must be lifted up for the disc change. But also a pivoting attachment for the table top will allow you to adjust the depth of cut. To solve the problem, the author hinged the tabletop on strong gate hinges. On the other side is a stop in the form of a bolt, this bolt can adjust the angle of elevation of the table top.

For the longitudinal sawing of boards, we fasten with clamps to the table, a guide angle.

With such a circular machine, you can dissect boards, slats, as well as saw blanks made of wood.

The entire process of making a circular saw, is also shown in this

The materials used to make the machine:

The process of making a circular saw is shown on the following picture

Also we need the axle, the housing bearings, a couple of pulleys and the belt.

A pulley is installed on one end of the axle, and on the other end there is a flange for mounting circular saw blades.

The body bearings are bolted to the frame.

Using a piece of sheet steel, let’s make a platform for the motor mount.

Make a table top of sheet steel, it is better to take a thicker metal, so it does not bend and do not affect the cutting process.

Under the sheet of steel the author made rests from pieces of pipe, the sheet should be raised above the axle and bearings.

Certainly, the table top should be lifted up for disk replacement. But also the swivel tabletop attachment will allow you to adjust the cutting depth. To solve the problem, the author hinged the tabletop on the sturdy hinges for the gate. On the other side there is a stop in the form of a bolt, with this bolt you can adjust the angle of elevation of the table top.

For the longitudinal sawing of boards, we fasten with clamps to the table, a guide angle.

With this kind of circular machine, you can dissect boards, slats, as well as saw blanks made of wood.

The whole process of making a circular saw, is also shown in this