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How to make a circular saw with your own hands from a hand-held circular saw. How to make a circular saw from a circular saw with your own hands How to make a machine from a circular saw

In the household, a circular saw always comes in handy. Major repairs are a costly and troublesome task. Not everyone can afford to buy expensive tools for processing wooden materials. A DIY circular saw allows you to carry out safe work and speed up the construction process. A saw made by yourself has a number of advantages, such as reliability, efficiency and sharpening for immediate needs.

A circular saw

Purpose of a circular saw

Before you begin assembling the machine, you need to clearly define its purpose. For preparing firewood and simply cutting large pieces of wood, a firmly fixed table with a slot for a saw is sufficient. This type is common in villages and rural areas; the machines are not safe and have increased functionality.

For a more varied range of carpentry jobs, you will need a better option. The circular machine must be equipped with a coordinate table with special guides, this allows you to change the degree. The manufacture of small-sized products requires increased safety. Speed control is installed and discs can be changed.

Design features of a circular machine

Circulars of any fixed type consist of main parts.

Table for connecting mechanisms. An assembly combined with higher power engines is preferable to a table made entirely of metal. The surface of the table must be made level with your own hands, for a higher quality product at the end.
The engine in most cases is used from what is in stock. Electric motors designed for long-term operation from the network will be preferable to commutator drives.
The shaft is the most critical component of the circular. Finished products are used most often; in other cases, the assembly is made on a lathe. It is important to calculate the mounting holes and eliminate runout.

A table for a DIY table saw can be used as a cutting machine. The cut cannot reach more than 8 cm, so larger jobs will require the use of a larger machine.

Stationary machine with your own hands

To perform everyday or one-time tasks, a hand-made circular saw is quite suitable. Small-volume sawing work does not imply heavy loads on the disk drive. The compact tool has small dimensions, which makes it possible to put it away after finishing work in a certain place. An experienced carpenter will need to make a large stationary type circular saw.

Making a stationary circular saw with your own hands will require precision and literacy from the master. Drawings presented in many types of literature will help in manufacturing. It is worthwhile to treat every component of the unit competently and carefully, because the circular machine is used at high speeds with a cutting tool.

Circulation table

Saw blade

The design of a DIY circular saw must contain a saw blade. The working surface of the disk is set to one third of the total diameter. For example, with a diameter of 210 mm, the disk should protrude 70 mm from the table. Parts with greater thickness will require a powerful motor, from 1 kW. A miniature circular saw will not cope with such tasks.

The splitting knife installed on some models serves to prevent short circuits and jamming during operation. It is located at the back a few millimeters from the teeth of the saw blade. The device may also be needed when making a circular saw with your own hands.

Adjustable side support

Any type of work will require a stop. The side support is made of a block of dense wood. In other cases, it is possible to make it from a metal corner. The arrangement should be slightly longer than the table structure. The stop is installed using bolts. The template is installed between the table and the cutter for precise installation and better settings.

Shaft

Homemade shaft

The most important part of the design is the shaft mounted on the circular saw. A self-made shaft for a circular saw can damage the structure and cause injury. The reason for this is runout, which cannot be avoided when making a shaft using artisanal methods. The manufacture of the shaft should be entrusted to a specialist with good turning equipment. You should remember that there is a cutter that needs a seat. The holes must be symmetrically machined and machined.

Finished shafts are sold in specialized markets. Preference should be given to parts with a self-aligning bearing. Otherwise, the conventional mechanism may soon render the circular machine unusable.

Broadcast

There are several types of gears that can be used in the design of a DIY circular saw:

V-belt transmission;
mechanism consisting of gears.

The preferred option is to use a belt drive. Using a mechanism with gears can lead to jamming if a foreign body enters and injury to the worker. When choosing the pulley diameter, the maximum number of revolutions of the saw blade is taken into account.

Motor

In most cases, homemade machines are equipped with an engine from an old washing machine. The main features are increased service life and efficiency. The speed of such engines is not high, which makes working on a circular saw assembled with your own hands safer, longer, and has a positive effect on the result. The use of a special three-phase motor implies the presence of a 380 Volt network. If one is not available, you will have to use a starting and running capacitor, which leads to additional costs.

Circular saw from a grinder or circular saw

When working with small workpieces, it is enough to get by with a small circular saw. A circular saw is made with your own hands from available power tools; you will need a grinder or a circular saw.

There are many options for stationary use of improvised tools. It is enough to secure the device from the bottom of the table to access the material to the disk. The height is adjustable depending on the workpiece, but for safety reasons should not exceed one third of the size of the saw blade. This installation option is not available for the switch; it is necessary to modify the device for convenient operation.

A fairly common option is to use a frame on guides. The simple design allows you to use the tool to work at any angle. It consists of two parallel metal pipes or angles on which the saw is mounted.

A hand-made circular saw makes the work you do faster and more economical. Such a device will be needed during major repairs and other actions related to cutting wood. The simplicity of the design, the possibility of using scrap materials, makes the cost almost zero, and making it yourself allows you to add the necessary functionality for the job.

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How to make wood cross-cutting machines with your own hands DIY disc sawmill

A stationary circular saw is a machine that should be in the workshop of every craftsman who works with wood. With its help, you can quickly and effortlessly saw a board, cut a workpiece of the required size, or cut firewood.

A home craftsman simply must acquire such a machine. It is not necessary to buy it; a homemade circular saw is guaranteed to cope with the volume of work in a home workshop, and will cost a significantly less amount.

Circular saw device

Being a truly useful tool, the circular saw has a fairly simple design. Its main components:

bed – frame on which the main units are mounted;
tabletop with a slot for a disk;
engine with rotation transmission system;
cutting tool, disc with teeth.

Optionally, the device can be supplemented with a pusher, which ensures progressive movement of the workpiece towards the disk, and various lifting mechanisms that regulate the cutting depth.

The principle of operation of a circular saw (circular saw) is that the rotation of the electric motor shaft is transmitted to the cutting tool, a disk with sharply sharpened teeth. The center of the disk is located below the level of the tabletop, only a segment of it is removed from it. The workpiece is brought to the rotating disk, the teeth bite into the wood, creating an even cut.

A simple circular saw from a grinder or circular saw

An angle grinder (grinder) is one of the most popular home craftsman tools; with its help it is easy to cut metal and clean welds. In addition, using a wood disc instead of a standard abrasive disc, the grinder can be turned into a hand-held circular saw (it is also called a parquet saw), and by making a frame with a table, it can be turned into a stationary circular saw.

Required accessories

To work you will need:

multilayer plywood with a thickness of 10 mm or more;
switch and wire;
countersunk head bolts;
screws;
wooden block 40x40 mm.

You also need to prepare a drill or screwdriver, hammer, screwdriver, pliers, ruler and pencil. Using these tools you will have to make a circular saw with your own hands.

Of course, you must not forget the grinder itself or the hand-held circular saw. At the first stage, it will help to cut the material, and then it will take its place as the working body of the circular saw.

Sequencing

The first step is to make the body of the circular. Thick plywood is perfect for this; you can use any pressed wood boards. You will need to cut four rectangular sheets, size 40 x 80 cm. They are used to assemble a box with a square 80 x 80 cm at the base. For ease of assembly and reliability of the structure, four bars are installed in the corners.

The resulting box is closed on top with a tabletop. It can be made from the same plywood, but it is better to use some sheet material with a laminated coating. This guarantees the durability of the machine and ensures ease of use of the homemade circular saw.

A cut is made in the tabletop to allow the disk to come out, and holes are drilled on the sides for attaching the tool.

The grinder must be securely fixed under the tabletop. The design of the latch can be very diverse, it all depends on the configuration of the machine itself. The main requirement for fastening is that it must securely hold the angle grinder without allowing it to move.

The simplest fastening may look like this: two metal squares, a grinder is fixed between them with a steel clamp.

Two holes are drilled in the upper shelves of the angles holding the angle grinder. The structure is secured from below to the tabletop using countersunk bolts. All that remains is to block the power button and connect the angle grinder via an external switch.

In the same way, you can make your own circular saw from a circular saw. In this case, the work is noticeably simplified due to the fact that there is no need to invent a fastening. It is enough to make a cutout for the disk, drill holes along the holes of the plate with a hand-held circular saw.

Miniature machine made from a washing machine engine

The circular is distinguished by its extreme simplicity and availability of materials for its manufacture. Perhaps its only expensive part is the electric motor. Stationary machines are equipped with a powerful asynchronous motor, which ensures cutting of thick wood of any species, but in a home workshop you can limit yourself to less power.

Note! To cut boards of medium thickness, it is enough to make your own circular table driven by a washing machine motor.

This design has a number of advantages. An engine from an old washing machine is inexpensive; moreover, a similar unit can probably be found in a home craftsman’s household. Connecting this motor is not particularly difficult; there is no need to look for circuit diagrams or do soldering. With all this, the power of such a unit is quite sufficient for most types of work.

The machine diagram can be simplified as much as possible by eliminating the belt drive. In this embodiment, the cutting tool will be mounted directly on the motor shaft. The base of the desktop mini-machine will be a frame assembled from a block with a cross-section of 40 x 40 mm. If desired, it can be welded from a corner or profile pipe.

Part of the body of an old TV, coated chipboard, is ideal as a stand (tabletop) for a circular table. As practice shows, this part is quite durable, and thanks to the varnish coating, it does not prevent the workpiece from sliding.

Using a jigsaw, two parallel cuts are made in the tabletop perpendicular to the cutout for the disk. A movable square will slide along them, playing the role of a side stop. It will help you make an even cut, if necessary, at a given angle.

Stationary machine

Those who plan to get serious about woodworking should think about making a full-fledged stationary circular saw. This should be a separate unit installed on a workbench, equipped with a powerful motor, with the ability to quickly replace the disk. Making such a circular with your own hands will take time, but it will definitely pay for itself.

Despite the apparent simplicity of this device, before starting work it is worth creating a drawing of the machine. This will allow you to clearly see the future unit and choose its optimal configuration.

bed

The basis of any machine is the bed, the frame on which all the main parts are mounted. The frame of the circular saw must be stable and reliable, which is why it is made of metal. It is preferable to use a profile pipe or a thick-walled angle. Welding is used to connect parts. If a collapsible structure is planned, a bolted connection is suitable.

Buying a suitable material will not be difficult; in any specialized metal store you can pick up both pipes and an angle. Those who want to save money can be advised to contact scrap metal buyers. You can buy the same thing from them, only cheaper.

Tabletop

The best material for making the tabletop of a professional circular table is metal. Steel and aluminum-based alloys are excellent. For a budget option, you can limit yourself to thick multi-layer plywood covered with sheet iron. In any case, the surface of the tabletop must be smooth, resistant to friction and not bend under a weight of up to 50 kg.

A groove is made in the tabletop for the disk. It can be done in two ways. You can make a cut in a single sheet, or you can assemble a tabletop from two halves. The second method is preferable for a metal tabletop, which is difficult to cut into at home.

If desired, you can make a sawing machine for work outside the workshop; for this it is enough to provide the possibility of installing a low-power gasoline engine; it can be removable.

Rotation transmission

The optimal drive for a circular saw is a V-belt drive. Two pulleys are used, one on the engine and one on the drive shaft. It's convenient and safe. There is no direct connection between the motor rotor and the disk; if the tool jams, the belt will begin to slip, signaling the need to turn off the power. In addition, using pulleys with several grooves of different diameters, you can adjust the speed of the saw, choosing the optimal mode for different types of wood.

Rotation from the motor rotor is transmitted to the shaft. This is one of the most important parts of the circular. It is unlikely that you will be able to make a shaft yourself; it is better to buy a ready-made one or order it from a turner.

The shaft is mounted on bearings. They must be of a closed type: a circular saw is a sawing place and open ones will not last long.

Machine with pendulum engine suspension

Those who can boast of the ability to work with metal can be advised to make a circular saw with a pendulum engine suspension. The main feature of the device is that the motor, shaft and cutting disc are installed in one common frame. On one side it is hinged to the frame, the second is held in place by a screw with the ability to adjust the height. By changing the length of the screw, you can adjust the height of the disk exiting the tabletop.

This system allows you to adjust the cutting height, as well as use discs of different diameters. If, instead of an adjusting screw, you use a probe placed on the tabletop, you can get a simple copying machine. The feeler gauge will allow you to adjust the cutting depth according to a certain pattern. This fairly simple modification will turn a simple circular saw into a real woodworking machine. With this device you can not only cut the board into the necessary pieces, but also make precise cuts and make various selections.

– a necessary and useful tool in the arsenal of a home craftsman. It is especially necessary for those who work a lot with wood. To make a circular saw on your own, all you need is a great desire, the necessary tools and the ability to work with metal.

Serious tool

A self-built circular saw can be a stationary or tabletop model. At their core, they are one and the same. The devices differ only in the height of the frame. What height to choose will depend on the intensity of use of the workplace. If the saw is rarely used, then it can be made in a tabletop version. If necessary, the structure can be disassembled and free up space in the workshop for other work. If a craftsman constantly works with wood, then a stationary circular saw is more suitable for him.

The stationary structure consists of several main components: a table, a gear disk, a motor, an adjustable side stop and a shaft.

To make it you will need:

Sheet of metal with a thickness of at least 8 mm.
Metal corner 45x45 mm.
Electric motor.
Metal disc with teeth (diameter 400 mm).
Ball bearings.
Welding machine.
Wooden block.
A piece of plastic or laminate.

Making a circular saw with your own hands will be much easier if you first draw up a drawing of the future structure and indicate all the necessary dimensions. All parts are manufactured in accordance with the drawing and then assembled into a frame using a welding machine.

ABOUT longitudinal cutting of rolled products.

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Assembly of a stationary structure

The main part of the saw is the table. The tabletop must be made of sheet metal. Its dimensions depend on the preferences of the master. The main thing is that the circular saw with your own hands is stable and comfortable to work with. If additional space is needed to install other devices, the surface can be covered with a sheet of thick plywood (Fig. 1).

Particular attention must be paid to the height of the guide. It is most convenient when the guide protrudes above the table by 120 mm. Experience shows that with this arrangement it becomes possible to process boards not only in width, but also in thickness.

Figure 1: A sheet of thick plywood is ideal for covering the surface of the countertop to accommodate additional accessories.

To make a guide for a circular saw, you will need 2 pieces of metal corner and a clamp that is welded to them. The metal part is deliberately made from two parts of the angle. The solid angle will guide you when the saw is working. You need to screw a wooden block to the corners using bolts and self-tapping screws, and attach a piece of plastic or laminate 120 mm wide to it. The length of the laminate piece should match the length of the table. This part should be set at an angle of 90° relative to the tabletop (Fig. 2).

A DIY circular saw should be height adjustable. In some designs, the table can be adjusted, but it is more convenient for work when you can raise and lower the saw itself.

A single platform is required to install the motor and shaft. It should be installed on one axis in the form of a rocker arm. It is fixed with a piece of bolt with a diameter of 15 mm, which is welded to it. On the side of the saw you need to weld a metal plate in which you first make a hole. Its shape should be oblong along the direction of the rocker. A bolt will pass through it, onto which a wing with handles should be screwed. The saw clamp is ready. If there is a need to adjust the height, the wing is unscrewed, the saw is aligned with the ruler and the wing is screwed back on. When using a disk with a diameter of 400 mm, you can process boards up to 240 mm wide (Fig. 3).

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Make other options

Figure 2. A piece of laminate must be attached to a wooden block, the angle of which should be 90° relative to the tabletop.

A do-it-yourself circular saw can be made manually. The easiest way to make it is from a grinder, making some improvements to its design. On the grinder you need to install an axial handle and a sliding stop.

To make a sliding stop, 2 pieces of corner will be needed. They are located on the sides of a disk with teeth, which replaces the abrasive wheel. The corners are attached with a gap of 3-4 mm. They are connected at the front and rear with bolts and nuts. To obtain clearance, washers must be used. The bottom edge of the corners should be rounded. Thanks to this, they will not cling to the objects being processed.

A do-it-yourself circular saw made from an angle grinder is equipped with a sliding stop. A clamp is attached to the body. It is made from metal tape. Its screed should be located at the bottom. A galvanized strip with a thickness of at least 1-1.5 mm is attached to the tape, on which a hole must first be made for the sliding stop bolt. Using washers, gaps are established between the working part and the side parts of the stop. The gaps must be the same size.

An axial handle is attached to the gearbox housing. To do this, the gearbox is disassembled so that you can determine at which points to make 4 holes for small bolts. The handle is made from a piece of pipe or rod and should have the shape of a staple. Its width is slightly wider than the master’s palm. At the ends with which it will be attached to the gearbox, it is necessary to drill holes for the bolts. It is not worth flaring the ends of the tube so that the handle does not bend during operation.

A piece of rod or tube protruding forward should be secured under the handle. Flare the end of the tube and make a hole for the axle 4-6 mm thick. The hole should be 4 mm larger. To make it convenient to work, a gap of at least 100-150 mm is left between the rod and the handle.

Figure 3. Diagram of a disk for a circular saw.

The next stage is the manufacture of the adjusting rod. To do this, you will need a piece of rod with a diameter of 4-6 mm. The end of the pipe is bent in the shape of a loop and slightly flared. Using washers at the front end of the stop, the same gap is established along the entire length.

The part of the rod that will fit into the hole on the handle must be threaded. Before inserting the rod, screw the nut onto it. The other nut is screwed on after assembly. The nuts will provide adjustment of the cutting depth. If necessary, they need to be released or tightened.

A stationary circular saw is an essential tool in a carpentry workshop - for those who perform carpentry work for their own needs or make various items to order. This stationary machine is easy to use – especially long and monotonous ones. With it, the master’s back is in a straight position, so he gets less tired.

Today, in stores, machines and tools are presented in a huge selection of models. However, they are too expensive for a simple carpenter, so to get out of the situation you have to look for other solutions. One such example is when a craftsman made a stationary saw with his own hands using a hand-held circular saw. Let's see below how he did it.

List of required materials:
hand-held circular saw;
plywood 11 mm;
M-8 bolts with a furniture head;
screws;
switch;
the wire;
timber 40x40;
furniture guides.

List of tools:
electric jigsaw;
hand-held circular saw;
drill;
screwdriver;
hammer;
screwdriver;
pliers;
ruler.

How to assemble a stationary circular saw

As we have already noted, the author used a manual circular saw to make his circular saw. At the same time, he made no changes to the design of the saw itself. In this case, the master made a table, attached the sole of the saw to the bottom of the tabletop - where the cut for the disk was made before. He drilled the holes and then sawed them. Taking plywood and 40x40 timber, I made a base.

After that, the author took plywood and cut out the tabletop. It is better that it is laminated or varnished, with a flat and smooth surface. As described, a cut was made, and holes were drilled in the corners for subsequent fastenings.

At the bottom of the tabletop we attach the circular saw using M-8 bolts. In this case, the bolt heads must be recessed into the plywood.

The author installed and connected the switch, fixed the start button on the saw in the pressed position, and connected the switch to the outlet. Therefore, there is no need to disassemble the saw, and there is no need to connect anything to it.

To make it more convenient to work with the machine, the craftsman made a movable stop on furniture guides.

The aluminum corner served as a longitudinal stop.

To adjust it, you should loosen the bolts and move it to the distance required for further work.

Those people who often do carpentry work for themselves or to order, simply need to have a stationary circular saw in their carpentry workshop. Working on a stationary machine is very convenient and, again, the back position is straight, which is important during long and monotonous work.

Today, stores have a large selection of machines and tools, but a simple carpenter cannot afford a couple of them and has to get out of the situation using natural ingenuity. For example, a master made a stationary saw from a hand-held circular saw, how did he do it? Let's look further.

Materials
1. hand-held circular saw
2. plywood 11 mm
3. M-8 bolts with furniture head
4. screws
5. switch
6. wire
7. timber 40x40
8. furniture guides

Tools
1. jigsaw
2. hand-held circular saw
3. drill
4. screwdriver
5. hammer
6. screwdriver
7. pliers
8. ruler

The process of creating a stationary circular saw.
And as was said above, the author made his circular saw from a manual circular saw, and no changes were made to the design of the saw. Here a table is simply made, and the saw sole is attached to the underside of the tabletop, where a cut for the disk is first made, holes are first drilled and then sawn. The base is created from plywood and 40x40 timber.

Then a tabletop is cut out of plywood; the author recommends using laminated or varnished, because the surface is even and smooth. As agreed, the cut is made, and holes are drilled in the corners for subsequent fastening.

A circular saw is attached to the underside of the tabletop using M-8 bolts, mainly the bolt heads should be sunk into the plywood.

The switch is installed and connected, the start button on the saw is fixed in the pressed position, and the switch is connected to the outlet, so there is no need to disassemble the saw or connect anything to it.