Circular Saw With Your Own Hands: How To Make A Circular Saw From A Hand Saw And Accessories For It According To The Drawings? How To Assemble A Circular Machine?

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

A circular saw is required in private households quite often, but buying an expensive tool for this is not at all necessary. You can make a circular saw with your own hands from available tools.

Basic materials and tools

To create a circular saw, you will need materials:

• pipe (45 mm);
• channel;
• corner "4" and "6";
• boards 30 mm wide;
• metal sheet up to 8 mm thick.

From the nodes you will need:

• engine;
• shaft;
• bearings.

The work cannot do without tools and materials:

• jigsaw;
• turbine;
• screwdriver;
• screwdriver;
• Scotch;
• a hammer;
• nippers;
• pliers;
• tape measure and triangle ruler.

How to do it yourself?

A circular electric saw for wood can be made with your own hands from various devices. There is an important condition: you should have the skills to work in metal.

From the grinder

Making a homemade stationary circular saw at home is easy. First of all, you should decide on the project, draw a diagram and make a drawing. The differences between stationary and tabletop homemade circular saws are in the height of the base . Before assembling a tool, you should think about creating a "table". It is usually made of wood (the thickness of the board is 3 cm) and covered with tin or aluminum sheet. Also for these purposes, a steel sheet with a thickness of up to 6 mm may be suitable. Crossbars are made from a corner (up to 80 mm).

The working disc protrudes beyond the table, usually by 35%, that is, for a 120 mm thick bar, the disc diameter should be respectively 370 mm. The power plant will need 1000 watts (possibly more). If the blanks are more massive, then a homemade circular may not "take" them . The stop is created from the corner "8" - this is a rather massive and durable structure that can withstand quite significant loads. The stop extends beyond the boundaries of the table by 4-5 cm. One shelf is processed from both sides, the remainder in this case should be equal to the length of the table.

A very important unit is the shaft - it is best to take it ready-made . If you have the skills to work on a lathe, then turning such a part is not very difficult. You will need to buy bearings with protection. It is better to put the pulley with a V-belt. A power plant from a refrigerator or washing machine can be used as an engine. Capacitors are usually installed oil-paper.

After the machine has been assembled from available tools, it should be tested without any stress. All elements must "get used" to each other in order to work in a single complex. During the testing process, some flaws may appear, they will need to be eliminated. For a homemade circular, an engine from a washing machine may be ideal.

Such power plants operate from a 220 volt network, they have good efficiency and an acceptable rotational factor . If you install a three-phase engine (it is powered by 380 volts), you will have to buy additional capacitors in order to reformat the unit for 220 volts. Sometimes units with a gasoline engine are used - such power plants have good efficiency, are unpretentious during operation.

The most important element in a homemade unit is the shaft . You can carve it yourself from a metal ingot. It is not difficult to make such an element on a lathe. At the same time, it is important to observe the centering of the part, so that then there is no unnecessary vibration of the mechanism. Special grooves are machined on the shaft, where the saw blade and pulleys will be attached. Sometimes recesses are also grinded for attaching knives. The size of the saw blade itself is directly related to the power of the engine. The diameter should be 3, 5 times the thickness of the product. There are also proven calculations: for 110 mm of material thickness, an engine power of 1 kW will be required.

Craftsmen often make a circular saw together with a jointer on one base. In this case, both tools can work from the same engine. The planer is capable of cleaning a wooden surface to a mirror-like shine, its presence in combination with a circular is more than appropriate.

From a hand-held circular saw

It is also easy to assemble a circular saw from a hand-held circular saw. The slide stop can be made from corners that are mounted on both sides of the rotating element (disc with teeth). The slot width is usually up to 5 millimeters. All edges must be processed so that they are slightly rounded. All corners are made with crossbars, which should firmly bind them. Bolts and nuts can be used as fasteners.

A metal clamp should be attached to the body . The turnbuckle is mounted at the bottom of the unit. The clamp (up to 2 mm thick) in conjunction with the C-pillar is a single unit that can withstand significant loads. The stop is fixed at the rear of the unit. The washers that create the gap can be moved by adjusting the size of the slot between the disc and the sides of the stop.

The transmission is best done with liner belts - if a foreign object gets in, then when jammed, such pulleys will slip, which eliminates the likelihood of injury. A pulley with a large size is placed on the engine, a pulley with a smaller diameter is placed on the circular shaft - in this ratio, the optimal number of revolutions is achieved.

From a chainsaw

To make a circular saw from a chainsaw, you will need a metal canopy that will be mounted to the saw body. The engine is already available, so it will not be very difficult to make the unit. You will also need two channels with dimensions of 185x8000 mm. You will also need corners (55 x 100 mm) and two trim rails that turn with the soles up. At the base of the sawmill, holes of 16 mm are drilled, there should be a distance of one meter between them.

Screeds are made from the pipe (length - 255 mm). The fastening of the structure is carried out on bolts. Stands are made separately, the frame of the sawmill will be attached to them. It is important to monitor that all elements do not deform . The distance between the posts should be no more than one meter. Then the sawmill is equipped with a movable carriage. It is made of steel sheet 620x55 mm, corners are welded to the metal from below. Small bearings are mounted on the bogie. At the top, two corners should also be welded, a chainsaw is attached to them. Then a holder is made, which will work as a retainer for a bar or log.

You will need a pipe with a diameter of 45 mm. For work, you will need a hose that will be attached at a given height, which should not be more than the length of the pipe itself. In this way, the sawmill is made. A bar or a log of any section can be processed on such a unit.

From a drill

Drill is a versatile tool from which you can make the following aggregates:

• drilling mini-unit;
• lathe;
• mower;
• impeller.

Locksmiths in the service station even make winches from drills for lifting large enough loads. The drill is also actively used in construction, in particular in painting. Farmers often use a drill to install seedlings into the ground. The drill circular will be compact. To create a tool, you will need the following elements:

• bases from a board with a thickness of 2-3 cm;
• vertical supports;
• the shaft on which the disc is mounted;
• electric drive in the form of a drill.

Instead of a board, you can also use chipboard sheets with a thickness of at least 30 millimeters . On such material, a rectangle with a size of 310x255 mm should be cut out. Also, a 5 mm thick duralumin sheet is required for the desktop. This material is good because it has an acceptable stiffness coefficient and, at the same time, is light in weight. In the place marked with a marker, a hole of 165x12 mm is cut.

The fasteners for the drill itself can also be made by hand. The saw shaft assembly can be easily found on any construction market. During operation, a lot of dust will arise, so you should look for a bearing with protection - this will significantly prolong the service life. A circular saw from a drill is assembled according to the standard algorithm:

• all main parts are attached to the base;
• then the table is mounted;
• the drill is connected, test tests are done.

The equipment requires compliance with safety measures:

• the place of work should be cleared;
• the workpiece should work smoothly, without any delay;
• the machine must be equipped with a protective screen;
• garbage should not accumulate on the machine, it should be removed in time;
• it is necessary to do a preventive inspection of the unit, to lubricate it.

Such a mechanical device makes it possible to process not only wood products. If you put good cutters, then you can work with non-ferrous metals, PVC, chipboard, bars.

Homemade gadgets

A circular saw is not so difficult to make, problems can arise when fitting the knots. Choosing the right elements to make them work flawlessly is an important task. The shaft must have self-aligning bearings if the unit is used daily. The bearings themselves are best fitted with two rows of balls, which will be adjusted using a clamping nut.

The working surface must have a "grid" -marking . Without this coordinate system, precise woodworking is quite difficult. The protective cover must not be neglected - during operation it reliably protects the device from mechanical damage. A circular saw, when working with various materials, works in different modes, so it is advisable to have a device that controls a similar process. Several grooves should be made on the shaft so that it is possible to rearrange the pulleys, thus changing the speed.

The parallel stop is a necessary device for working with large-sized workpieces. You can make them yourself from plywood, boards or chipboard. The stop value usually does not exceed 25 mm. The stop is fastened with self-tapping screws or bolts.

When you have to saw bars or make several cuts from different directions, you need a stop that has the "P" configuration. At its base is a board 30 mm thick. Sidewalls 12 mm thick are screwed to the base. Thus, the stop is installed on a bar, the size of which from the cutting point corresponds to the size to the cutting disc. From two sides, it is pressed against the timber with clamps. If the timber is too massive, then rearrange it and make another cut.

There is also an edge stop that is in demand. To do it, it takes a lot of time and a good qualification of the master. Be sure to make a schematic drawing before starting work. This emphasis is made of plywood (20 mm), and a persistent bar is also made from this material. Manufacturing phases:

• longitudinal grooves for dowels are cut;
• the keys are mounted on a thrust bar;
• another groove is cut between the grooves made to secure the stop bar;
• another hole is made at the base, its size corresponds to the circular saw cutter;

The sidewalls are mounted, and there must be latches in order to securely fix it. To place an emphasis on the workpiece, the bar moves in the grooves and is fixed through the slot with clamps. It is best to immediately attach a ruler or tape measure to the bed - this greatly facilitates the work. The pusher is convenient for working with small workpieces - it allows you to clamp the part from both sides, which ensures accuracy in work. It is also important to do:

• elevator;
• riving knife;
• lifting mechanism.

If a three-phase engine (380 volts) is installed on the machine, then capacitors will certainly be required that can withstand a minimum voltage of 620 volts. These devices can be paper-based.

Capacitors are calculated according to the following scheme: per 1000 watts, there is 100 μF for a working type capacitor. The capacity of the starting capacitor must be ordered twice as large. It should be remembered that the SB trigger is a device that automatically returns to its original position. This is very convenient, because literally in a few seconds after the start, you can start a workflow.

Safety Tips and Techniques

In the course of work, you should adhere to the recommendations of specialists.

• you cannot work with wood in which there are metal fragments (nails, screws, etc.);
• marking of the material is possible only if there are special clamps or substrates (this is especially true for long boards and beams);
• boards and timber from two meters long must be handled by two people;
• when working with a disc, sharp movements or jolts should not be used, otherwise the device may jam, it may break;
• if the material has dimensions from 42 cm, then it is recommended to use a special pusher;
• if the wood is heterogeneous (there are branches and knots), then dissolve it necessary before work;
• always use gloves: both during operation and when cleaning the unit;
• do not accumulate wood waste on the machine - this may cause a fire or a short circuit.

The machine must not be operated under the following circumstances:

• no guide rail;
• no casing;
• too wide gap (from 10 mm);
• there are no fuses (wedging cutter, retaining fingers) that protect the employee from the workpiece that has fallen off;
• the height of the riving knife exceeds the height of the saw blade (from 6 mm), the distance of its mounting (17-110 mm).

The machine must have a chip collector. When working, be sure to use protective goggles. When changing elements on the machine, it must be de-energized.