Do-it-yourself Miter Saw: How To Make Wood And Metal Miter Saws From Hand-made Circulars? Advantages And Disadvantages Of A Homemade Broach Saw

2024 Author: Beatrice Philips | [email protected]. Last modified: 2023-12-16 05:33

The miter saw is created by hand on the basis of the existing equipment - a hand-held circular saw, an angle grinder (grinder). And when mounting disks of a specific type, a home-made device can be used to cut a profile on a metal-plastic base, pipes, which will increase the area of its use.

Varieties

Cross-sections are divided into the following types:

• pendulum;
• combined;
• with a broach.

The base of the pendulum device is the frame. A table is also attached to it, which is based on a rotation mechanism with a ruler. This mechanism solves the problem of setting the cutting angle with its adjustment. The cutting angle can be adjusted by moving the table in relation to the base surface. The saw component is held in place by a handle and is spring-loaded with a hinge. The pendulum moves the saw vertically.

In the combined modification, it is possible to change the cutting angle in two directions. The structure is the same as for the pendulum trimming, only one more hinge is added. As for changing the cutting angle in the horizontal surface, it can be changed in the horizontal direction, which is also opposite to the installed drive.

Crosscut with a broach allows you to translate the cutting component both along the circumference of the pivot axis and directly along the length of the cut. This is obtained due to the existing guides.

Tool creation

It is possible to make a miter saw with your own hands, taking the available equipment as a basis.

From a hand-held circular saw

The structure is common and acceptable for home construction. The body of the trimming unit is made of wood or iron. A base is constructed from plywood sheets (chipboard), on which a vertical rack is mounted, having previously cut holes in it to fix the facing. A pendulum-type device is made from a board and is attached to the base by means of a long bolt.

Having prepared a steel rod or corner, it is attached on top of the pendulum so that the end sticks out . Then a spring is taken, one end of it is fixed to the rear shelf of the corner, and the other - to the vertical post. The tension is selected empirically, but it should be enough to easily hold the circular saw in the hanging position.

Having removed the handle from the equipment, it is fixed on the pendulum in a previously prepared hole. The wires are placed in the slots prepared for this, and the power supply is connected. A small slot is made in the table top, and side stops are fixed to it at an angle of 90 °. If they are made to rotate, then it will be possible to cut the blanks at a specific degree. The unit is assembled, it remains to test it in operation. Using drawings, you can make anything, even a very complicated apparatus.

From the grinder

Miter saws are capable of cutting wood, iron, plastic and other materials.

The most famous facing is based on the use of an angle grinder.

If you manage to do everything correctly, your device with a broach will have the following options:

• disk rotation speed - 4500 rpm;
• cutting distance - about 350 millimeters.

If necessary, trimming is dismantled from the unit and is practiced as an ordinary hand tool. A big plus is that the homemade device is versatile and can be easily disassembled.

Let's consider how the manufacturing procedure takes place

1. Place the swivel mechanism of the angle grinder on the pivot of the implement wheel. Its fastening is made by means of a ball bearing. The recommended size is 150 millimeters, but larger ones will also work.
2. Ears are welded on the outer side of the bearing. They are designed to secure the base of the unit. Install with M6 bolts.
3. The holder should be covered with a protective cover so that chips do not fly on you during operation.
4. The broaching problem is easy to solve. To create it, take shock absorbers from a truck. Even if they are not in working order, this is not a problem. Remove any lubricant from the shock absorbers, drill holes for ventilation and cover with a mesh to prevent chips and dust from entering the cavity.
5. Install the soft start module. Thanks to it, you will not experience sudden jerks when starting the trimming.
6. The final stage is the installation of the saw blade guard.

Depending on the supplied disc, the unit can be used for metal or wood, for trimming pipes. But be aware that the power of the unit may not be enough to cut the ends of the pipes. Decide on the technical parameters of your angle grinder to find out if the machine is capable of cutting pipes, or if it is only suitable for working with wood.

This design has two important drawbacks

1. To adjust the precision of the cut, wood residues are used first. Then the traction is fixed, and you can get to work.
2. The unit makes a lot of noise when cutting pipes and working on iron.

Manufacturing a complex unit

There is a variant with a more complex and heavier design. She will precisely cope with the facing of metal pipes. At the same time, a self-made device does not require the use of a circular as an element of the unit. But for specific moments of work, it is better to keep the circular at hand.

Based on the selected components, you have the opportunity to make a high-power unit. To create it you will need:

• an electric motor with a resource of about 900 W, and if you need constant cutting of pipes, you can take a more powerful electric motor;
• sheet iron;
• metal corners;
• channel;
• hinge groups;
• angle grinder;
• welding machine;
• file;
• powerful spring.

When everything you need is ready, you can start assembling the end machine

1. The bed can be made using customizable supports, metal corners and bed racks.
2. A sheet of strong iron is used as a working surface. It is necessary to make holes in it and file them with a file.
3. For the manufacture of the pendulum rack, we use a channel and a welding machine. The structure is placed on an iron sheet. Approximate stand height 80 cm.
4. The base for the electric motor is made of iron sheet in the role of a stationary plate. The bed is necessarily mounted on hinges.
5. A powerful spring will serve as a stabilizer for the electric motor of the miter saw. If you find one, then you can refuse from the swingarm and belts.
6. The lifting bolt can be used to tension and adjust the belts. The pendulum can be made of steel so that the structure is strong and reliable.
7. The cutting tool will be a disc of the required diameter. For household tasks, as a rule, a saw blade with a diameter of 400-420 millimeters is enough.

Pros and cons

Homemade miter saws have both positive and negative properties.

The advantages of homemade units include a number of characteristics

1. The creation of a trimming machine will require an order of magnitude less money to be invested than in the purchase of industrial equipment for trimming wood, pipes, plastic and other things. Tentatively, specialists invest from 500 to 1000 rubles for re-equipment of an angle grinder in facing.
2. You have the opportunity to independently select the performance characteristics for the future end machine. Such parameters include the dimensions of the working surface, the power of the electric motor, the diameter of the discs, the depth of cut, and more.
3. The manufactured devices have a simple design. For the reason that you yourself assembled and disassembled the device, there will be no difficulties with finding breakdowns.

There are also disadvantages, among which several factors are particularly different

1. For homemade units, as a rule, they use old, useless materials, tools and devices. This negatively affects the quality and service life.
2. They don't often have a lot of power.
3. In some situations, saving on the purchase of an industrial design becomes far-fetched, because a lot of money is spent on repair work, refurbishment, preventive measures of a home-made unit.
4. You are putting yourself at risk, in terms of your own safety, by using a homemade trimmer.

Having an angle grinder, hand-held circular saw for wood and metal, you can freely make a home machine. Follow the instructions, follow the safety instructions.

Be sure to take into account the presence of protective fences, since working on such machines is not entirely safe.