Circular saw: tools and materials, sequence of actions

Owners of private houses and summer cottages often think about purchasing a circular saw. However, the average cost of the instrument reaches 7,000-14,000 rubles. Not every home craftsman can allocate such an amount from the family budget. In such a situation, you should not be upset, because if you wish, you can make a machine with your own hands from a circular saw.

Using a circular saw you can quickly saw logs and unravel boards

Circular saw device

Before you begin making the tool, you should familiarize yourself with the structure of the circular saw.

The design of the machine consists of:

upper protective casing with a hole for sawdust ejection;
the housing part in which the start button and electric motor are located;
a lower protective casing that automatically closes the cutting element after it leaves the workpiece;
saw blade;
parallel stop;
machine support sole;
depth regulator;
sole angle regulator.

As soon as the device is connected to the network and the start button is pressed, current will begin to flow to the electric motor.

Attention! Manufacturers offer a variety of circular models with wide functionality. Before you create a tool yourself, you can study information about how professional tools are made.

Advantages of homemade equipment

The main advantage of a homemade device made from a circular saw is its simplicity of design. The master may not look for ways to transfer motor rotation to the spindle, because the design of the circular saw already contains the necessary parameters.

If you use a high-quality model of saw to make the machine, the tool will perform cuts much better than budget models of circular saws.

Note! By making a homemade design at home, you can save money.

List of materials

As for manufacturability, it is quite easy to design a sawing machine, therefore, subsequent costs for its maintenance will be minimized. Below is a list of materials that you will need to assemble such equipment with your own hands:

metal sheets (σ=3...5 mm);
square pipes;
2 electric drives (one with a power of 500 kW, the other with a power of 200 kW);
flywheels and belt drives (automotive ones can be used);
electrical cable;
automatic switch.

Three-millimeter sheet metal is used as cladding for a body made of “square” pipes. Usually, the frame has the form of a welded cube; inside it, using the same rolled pipes, a holder for the motor is made. The dimensional characteristics of the base are calculated individually; you should not forget that the working surface will be proportional to the size.

What manufacturing options are there?

There are several ways to make a circular saw at home. Among the most popular methods it is worth highlighting:

installation of a manual circular saw on a machine made of timber;
using a grinder with a steel disk to perform the drive function;
installing the motor of an old washing machine on a wooden surface.

If the master plans to use a homemade product to unravel boards of considerable thickness, it is necessary to equip the machine with a high-power engine. Only such a device will be able to cope with tasks quickly enough and will not delay the master.

To cut timber longer than 2 m, you need to use a stand

Selection of materials and parts

When creating a homemade circular saw, it is necessary to maintain an optimal balance between its functionality, safety during operation and manufacturing costs. To achieve this, you should select materials and parts with the desired characteristics. To reduce costs, you need to start from old or unused equipment that is available.

Materials for making a bed with a table

To make a bed (frame), you can use a channel or metal corners (sizes from 25×25 mm to 50×50 mm are sufficient). If these materials are not available, then the most economical option is to purchase them at a scrap metal collection point. The legs of the machine will use water pipes or profile metal pipes.

When assembling the frame, it is also necessary to weld spacers at the corners to impart rigidity to the structure. To make it easier to move the machine, you can equip it with durable wheels (with a metal rim) equipped with locks. It should be borne in mind that the more massive the unit being created, the more stable it must be in order to avoid injury.

Metal pipe frame

The main requirements for a table for a circular saw: resistance to mechanical influences (vibration, shock), the ability to withstand workpieces weighing more than 50 kg without deflection, and surface smoothness . These properties characterize sheets of the following materials:

become;
duralumin;
silumin;
PCB;
moisture-resistant plywood;
organic glass.

If you use moisture-resistant plywood, then it should first be covered with zinc-coated sheet metal. The use of chipboard or OSB is not recommended due to the instability of these sheet materials to vibration influences.

Important! The strength of the table is of great practical importance. If it cracks or becomes distorted due to deflection, the disk may jam. This can lead not only to damage to the workpiece, but also to injury.

To carry out various work (for example, cutting logs into boards), you need to equip the table with a side support. It performs the same function as a guide bar for a hand-held circular saw: it ensures even sawing of lumber. Moreover, its use makes it possible to obtain workpieces of different sizes.

The guide stop must be strictly parallel to the disk to avoid jamming of the latter. It can be made from a wooden block or a metal corner. In the first case, only hardwood should be used. To be able to adjust the working gap, the stop must be removable. It can be fixed using clamps or in special grooves (bolts) made parallel to each other on the working surface of the tabletop.

Selection of engine and starting equipment

It is easiest to use a single-phase electric motor as a drive for the considered version of a homemade circular machine. Its power must be selected taking into account the upcoming load. Indirectly, you can navigate by the diameter of the installed disk:

if it is 350 mm, then for normal operation of the unit you need an electric motor with a power of 1000 W;
for a disk with a diameter of 170 mm, a 500 W motor is sufficient.

In the latter case, you can make a drive mechanism from an engine from an automatic washing machine. It is able to work for a long time at an average load level. For disks with a diameter of 350 mm, an electric motor from an industrial ventilation unit is suitable. It should be secured firmly to ensure proper engagement of the belt drive. For this reason, it will not be possible to reduce the level of vibration by installing the motor on shock absorbers: it will constantly oscillate.

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You can also equip homemade equipment with a three-phase electric motor (380 V) of suitable power. To start it from a 220 V network, you will need to additionally install working (phase-shifting) and starting capacitors into the electrical circuit. It should also be taken into account that the engine power will be less than the nominal value indicated on its plate or in the passport.

Starting equipment should be selected based on the power of the motor, on which the maximum current in the circuit will depend. A good option is to use a start button in conjunction with thermal protection - this will protect the electric motor from burning out the windings if the current increases when the disk jams . It is better to install the protection in a separate electrical panel attached to the side panel of the machine on the convenient side.

All connections must be well insulated so that the wires do not short-circuit to the frame of a homemade circular electric saw. The on and off buttons should be pressed without any effort. Due to the frequent storage of equipment outdoors, it is necessary to protect the electrical part well from getting wet. The simplest thing is to cover the installation with oilcloth or similar waterproof material.

Gear, shaft and disc

To transmit rotation from the electric motor to the disk, the best option is to use a V-belt in conjunction with pulleys from the car engine. The use of gears is not recommended for safety reasons. This is due to the fact that if the disk jams, the belt will simply slip, and the gear drive, due to its rigidity, can cause failure of the entire drive unit.

It is better to entrust the manufacture of the shaft to a specialist by ordering it from a professional turner. Moreover, when you plan to make a circular electric saw more functional by equipping it, for example, with a plane. But the simplest option is to buy a ready-made factory-produced part. A sample of it is shown in the photo below.

It is recommended to use self-aligning ball-type bearings together with the shaft. The mounts for them will fit from the car hub kit. In this case, the bearings should be well protected from dust.

It is easier to buy a disk for a circular machine ready-made than to make it from a sheet of tool steel. The problem is one of balancing. An imbalance of the saw during operation of the equipment leads to its rapid failure and reduces the level of safety of the work process. If you have a circular saw for wood, you can remove the saw blade from it.

It is necessary that the diameter of the disk corresponds to the corresponding parameter of the sawn timber: for example, for 100 mm logs you will need to use a saw measuring approximately 350 mm. This is due to the fact that the disk should not protrude more than a third of its diameter above the working surface of the table.

Ignoring this requirement not only leads to a deterioration in the quality of sawing workpieces, but also increases the possibility of injury.

A simple circular saw blade

The circular saw is considered one of the most popular tools for home craftsmen. With its help, you can trim wooden blanks, cut timber at an angle, align boards while laying the floor, etc. Using this tool, you can make a simple circular saw with your own hands.

Required Tools

When working on the creation of a small-sized tool, the master uses screws, multi-layer plywood, the thickness of which reaches 10 mm, and bolts with countersunk heads. You will also need to stock up in advance:

wires;
switch;
screwdriver/drill;
hammer and screwdriver;
pliers;
a hand-held circular saw (you can take a domestic Interskol or another);
ruler and a simple pencil.

Using the materials and tools listed above, you can create a simple circular machine with your own hands.

Sequencing

Below you can find information on how to make a circular saw with your own hands from a hand-held circular saw.

Step by step process:

To make the body part of the circular, rectangular sheets are cut out of plywood, the size of which is 40x80 cm. You will need 4 identical sheets from which the box is assembled (the dimensional characteristics of the square at the base are 80x80 cm).
The box is covered with a tabletop cut from plywood.
You will need to make a cut in the tabletop, which is necessary so that the disk can come out.
Holes are drilled along the edges of the cut to secure the tool.
The design of the latch can be any. The main thing is that the circular saw does not move during operation. If desired, you can attach a pair of metal corners and secure the tool with a clamp inserted between them.

By screwing a threaded bolt into the side handle, you can further secure the tool. This will help improve security.

Do-it-yourself parallel fence for a circular saw

The parallel stop is a mandatory device on a circular table; without it, it is almost impossible to make an even cut. You can make it yourself as follows:

A U-shaped profile should be made from three strips of laminated chipboard; inserts should be placed and fixed inside, which will add rigidity. The result will be a square section.
A guide channel is made from two parallel slats, which is bolted to the end of the table in a position perpendicular to the saw blade.
An inverted T-shaped structure is then made from MDF, which is screwed to the stop and inserted into the channel.

You can make a parallel stop for a circular saw yourself

Important! The width of the channel should be such that the side of the T-shaped element fits tightly into it.

To fix the stop of a homemade circular saw made by yourself, it is convenient to use the original slots. Threaded bolts, nuts and wooden washers are suitable as a locking mechanism; you will need a hole in the bottom plane of the stop. Tightening the bolt helps to securely press the stop to the table top. This design allows you to quickly and easily set the required cut sizes.

Stationary machine

If a master plans to engage in wood processing professionally, he should take care in advance about making a stationary machine. Before converting a hand-held circular saw into a stationary one, it is worth creating a drawing of the unit, allowing you to choose the optimal configuration of the device.

bed

The bed is the basis of the machine. It must be stable and durable. It is advisable to make the base from metal.

It is best to use profile pipes or thick-walled angles.

For reference! If you want to make a folding structure, it should be secured with bolts rather than welding.

Replacement of saw blades is carried out only after the machine has been switched off

Tabletop

The tabletop should also be made of metal. For this purpose, you can use steel or aluminum-based alloys. The tabletop must be made smooth and resistant to friction. It should be strong and not bend under a weight of 40-50 kg.

You will need to make a groove in the tabletop for the disk to exit. To do this, the master must make a cut in the metal sheet.

Motor

Depending on which disk will be used, you need to select a motor for the circular machine. In the case of using small disks, the diameter of which does not exceed 170 mm, it is worth purchasing electric motors with a power of 0.5 kW. For larger disks it is worth using a motor of more than 1 kW.

Rotation transmission

A V-belt drive can be considered the optimal drive for a circular drive. One pulley will be located on the motor, and the other in the drive shaft area. Due to the fact that there is no direct connection between the motor rotor and the disk, in a situation where the belt begins to slip, the power to the unit will be turned off.

The use of friction wheels with grooves of different diameters allows the master to regulate the speed of the unit. Rotation from the motor rotor will be transmitted to the shaft.

The shaft must be mounted on closed bearings

Making a table top for a circular saw

Assembling the table begins with making the tabletop.
The plywood sheet is marked so that the two edges of the lid are the same size as the edges of the iron sheet. Plywood is cut out using a hacksaw or jigsaw. The edge of the cut can be processed with a milling cutter, but this operation is not necessary. Since the main parameter in the frame is reliability, and not an attractive appearance. The tabletop is rubbed “roughly” with sandpaper.

At the bottom of the tabletop there is a slot for a circular circle . To do this, you first need to measure the dimensions of the sole of the unit. The easiest way to do this is to unscrew the disk from the device and simply circle the desired part of the saw. These measurements are required to determine the seat.

Using a hand cutter, the bars are selected to a depth of approximately 0.9−1.1 cm. If you do not have a cutter, then this work can be done using a chisel, but it will take much more time.

Then, when the seat is made, try the saw on and, if necessary, adjust the recess. Mark the slot locations for the circle and fixing the fasteners. If you need the circle to rise and fall, then you need to install a pendulum mechanism for the tabletop.

In this case, the slot must be made in the shape of a truncated pyramid. In this case, the hypothetical top of the pyramid will be directed downward. The frame itself for the lifting mechanism is best made from steel corners , which are welded to each other.

Making a table frame

The markings for fixing the transverse and longitudinal slats, which serve as stiffening ribs, are best installed on the underside of the tabletop. The planks themselves are made from timber. You will need:

Two transverse parts, length equal to the width of the table top minus 7-9 cm on each side.
Two longitudinal ribs, the size equal to the length of the lid minus 7-9 cm on each side.

Then you need to make nests for the screws . The slats must be fixed on the lid so that the tabletop extends 7-9 cm beyond the edges of the frame. The fasteners must be as reliable and durable as possible.

The first fastener should be installed approximately 40-50 mm from the edge of the rail. The distance between the screws is approximately 23-25 cm. All parts must be drilled through . The self-tapping screw is attached to the side of the lid so that its head is completely recessed into the wood.

First, the transverse ribs are secured. To make the table top as strong as possible, the edges of the slats must first be coated with wood glue . The structure is fixed with clamps, and without removing them, screws are screwed in.

Allow the tabletop to dry completely. Afterwards, the longitudinal slats are installed in the same way. Then the parts of the frame are pulled together, installing two fasteners on each side. Now the clamps can be removed.

Machine with pendulum engine suspension

This type of machine is considered the most advanced type of circular saw. The presence of a pendulum suspension makes it possible to achieve smooth operation of the unit. When using the machine there will be no jerking, and the belt will be tensioned well. The homemade product practically does not vibrate, which has a positive effect on the service life of the unit.

The main feature of the device is the location of the engine, shaft and cutting disc in a common frame. On one side it is fixed to the frame using a hinge, and on the other it is held in place with a screw, the turning of which allows the master to adjust the height of the disk exit from the tabletop.

A platform fixed on one side, on which the motor is installed, performs the functions of a pendulum. The other end of the platform is spring-loaded. When the motor turns on, the platform begins to dampen vibrations and the motor begins to tighten the belt.

Dust removal system for a homemade sawing machine.

The saw mechanism is covered from below with a casing made of plywood and hardboard. Most of the sawdust ends up here when the sawing machine operates; at the bottom of the box there is a hole where you can place a bucket or bag to collect dust. The hole can be plugged with a stopper for small amounts of work and sawdust can only be collected in the box. The casing itself can be easily removed for shaking out and cleaning. The removable casing covers only the area where the cutting disk of the machine is located, and the engine is located in another compartment and is not exposed to the destructive effects of dust. During intensive work, a lot of sawdust accumulates in the casing, which indicates good dust protection. Otherwise, all this dust would fly around the room. It felt like there was much less wood dust than when using a circular saw without a guard. Future plans to improve the design of the machine include equipping it with an impeller or fan for even better dust removal.

Removable box for collecting sawdust.

On the other hand, in the resulting empty space (where the engine is) there is an organizer for storing replaceable disks, a key for replacing them, and related tools. It turned out to be quite convenient, you don’t have to worry about where to store it all and you won’t accidentally forget to take something you need, otherwise all your work could get wasted.

Tips and safety precautions

It is very important to use a homemade structure correctly, which will make it possible not only to extend its service life, but also to avoid injuries.

It is not recommended to cut workpieces with knots and icy areas.
Brushes must be used to clean the work surface.
The workpiece must be fed smoothly, without making sudden movements and without trying to push the beam through faster. If you ignore this advice, the disc will break or get stuck in the wood.
It is unacceptable to push the remaining parts of small-sized workpieces with your fingers.

It is important to systematically remove chips from the working area of the unit. In addition, it is worth monitoring the condition of the disc teeth. If the teeth are set, the disc must be replaced or given to a specialist for sharpening.

When working on a circular saw, you must wear glasses

When starting to manufacture a machine, it is worth familiarizing yourself in advance with information on how to make a stationary one from a manual circular saw. A step-by-step guide will help you avoid mistakes that craftsmen often make during their work. Following the advice of experts, you can make a unit that will delight you with power and will expand the list of technological tasks available for performing.

Homemade devices for precise cutting of wood.

Several devices necessary for high-quality cutting of wood are made from the same material, that is, plywood. The stop rail with a lock ensures precise parallel cutting of wood. The workpiece is fed along a stop rail, which prevents the part from slipping and sets the size. The lock allows you to quickly reconfigure the machine.

Stop rail for parallel cutting.

The trimming carriage helps to saw off workpieces strictly at right angles, which is a necessary condition in the manufacture of furniture and other tasks requiring high precision manufacturing. Large sleds for trimming have also been made. The situation is that for almost every task, you can make a special device for cutting, which facilitates the work and increases the accuracy of manufacturing parts from wood. If you have plywood and straight hands, this is not a problem.

Carriage for trimming.