How to make a mini saw with their own hands

DIY Miniature Circular Saw

The name miniature does not mean that the power is not enough. The saw will be built on the basis of a 775 class electric motor. What to mount on drills and screwdrivers. The power of this home-made device will be enough to cut any wooden workpiece of a suitable scale.

This homemade tool will surely come in handy when making small wooden homemades and will make your life a little easier at all. It is sure to take an important place in your workplace.

  • Well, enough of the long preface, let’s move on to the assembly of the home-made device.
  • And so, for this homemade device you will need:
  • – Fiberboard panel- A pair of bearings of suitable size- Electric motor 775- Motor mount for 775 electric motor- Self-tapping screws- A shaft of suitable diameter (you can use the body from a simple ballpoint pen)- Axle for the main pair- A pair of “spur” and “pinion” (gears for belt drive)- Adapter for circular saw blade- Circular saw blade of suitable size- Belt- Wires
  • – Switch.
  • From the tools we will also need:
  • – Thermal glue. Soldering iron. Drill and drill bits. Screwdrivers. Angle. Ruler
  • – Marker.

To begin with, we need to cut a rectangle with the size of the sides 16×6 cm from the fiberboard panel, it will serve as a base for the motor mount. After that we need to take and install two identical bearings on the Woodchip board panel. The inside diameter of the inner ring of the bearing should be 5 to 6 mm.

To fasten them securely to the wood-fiber board of the bearing panel, the author printed out the fasteners on a 3D printer. To fasten the mounts we put them in their place (see “To fasten the motor in place”). To fix the bearings together with self-tapping screws on the base (see photo), leave marks with a marker and drill through holes with a thin drill bit.

After you have drilled the holes, let’s mount the bearings together with the fasteners to the base with self-tapping screws.

The next step is to mount the motor on the base. I advise you to choose the most important element of the DIY carefully. It is advisable to use an expensive 775 class electric motor with a small number of turns and the motor shaft should be on bearings and not on bushings.

I advise to buy this electric motor in a radio-controlled model store. There you can also buy a motor mount (this is how the motor is attached to the frame of the model) to attach the electric motor.

As you have already understood we will fasten the motor to the base with the motor mount, first we screw the motor to the base and then the motor to the motor mount.

Then we need a plastic tube, it will serve as a seal between the main axle and the installed bearings. For the best result the author decided to print a tube of the desired width on a 3D printer.

But you can use anything as a sealant, for example paper.

Put our sealing tube in place and put the axle inside (this axle is also available in the radio model store) and the axle should be tight.

After that we will put the “spur” (big drive pinion) on the “pinion” (small drive pinion) side of the electric motor on the newly installed axle.

You can buy big and small pinion gears at the radio model store, and you can play with the gear ratio by selecting the size of the main gear.

And on the back side of the axle we will install the adapter for the cutting disc. And put the belt on the main pair.

The most important part of the kit is ready. But it’s useless without a special table, so let’s make a table. To do this, we need to take a fiberboard panel with the size of 46×31 cm. On the panel you took you should cut a hole for the cutting disc.

To do this, we step back 16 cm from the edge and put a mark, having departed from the newly made mark another 5 mm, we put another mark. Using a marker and a square, we draw two parallel lines, like it is shown on the picture below.

Using the marks you have just made, drill a 5 mm hole with a drill bit between parallel straight lines, exactly in the middle. As a result we should have a window for the cutting disc.

Next we need to connect the table top you just made to the motor so that the disk adapter is exactly in the center of the newly made hole. And connect the two workpieces with self-tapping screws, pre-drilling the holes with a thin drill.

We made the table top, now we need to make the legs for it. To do this, and fiberboard panel cut two equal squares with the size of the sides 20×20 cm. And to keep the legs of the table from moving apart, you should make a kind of spacer by cutting a rectangle with sides 35×5 cm. Now we screw it all together with self-tapping screws.

Then, to make it easier to use the circular saw, you should install the switch. For this we take a pair of wires and solder one end to the contacts of the electric motor, the other end to the power supply, and the second wire should be soldered to the power supply through the switch. The switch itself with the help of hot melt glue to a convenient place.

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A through-hole was drilled into one of the legs so that the saw blade could be guided through the hole to the power supply. But you can also install there the connector for the power supply (if you have one).

Then mount the blade. We will use a 4 inch disc. It should be noted that the disk should be installed and rotate in the same direction as indicated on the disk or in its user’s manual.

The saw itself is ready, but it needs one important detail, which usually helps us to cut parts accurately and evenly. To make it we need to cut rectangles with the dimensions 36×4 from the same fiberboard panel.5 cm, 2×4.5 cm and 3×4.5 cm. The three just made pieces should be joined together with hot melt glue as shown in the photo below.

After that you should drill a through hole for the clamping screw. Insert the screw into the hole we have just made and tighten it with the nut.

Everything is ready! As a result, we have a cool circular saw, which will come in handy for small jobs and will not take up much space at all.

Circular saw with their own hands, made from a circular saw or angle grinder: manual mini-machine and stationary design

A stationary circular saw is a machine that every wood craftsman should have in his workshop. With its help, you can quickly and without much effort saw a board, cut a billet with the required dimensions, saw firewood.

Construction of a homemade circular sawmill

The simplest variant of homemade mini saw includes a table and a cutting disk. You can also make such equipment yourself, but it will not have high performance indicators.

make, mini, their, hands

The main disadvantage of this type of construction is the need to feed the material by yourself. This can easily lead to violations of the geometric parameters of the future beam or plank. That’s why these machines are only used for sheet metal work and relatively small workpieces.

Angular type sawmill can boast a much wider range of functions. This equipment simultaneously makes two cuts in vertical and horizontal position. But it is much more difficult to make than the model mentioned above. Homemade circular sawmill has the following design features:

  • A moving sawing carriage. This element runs on special guides on a platform. It carries two motors with discs;
  • stationary platform. It provides for material clamps that prevent displacement of logs and their subsequent deformation during operation.

It is possible to make such an installation with the help of improvised devices and materials. It is important that the sawmill can withstand continuous vibration and load.

If the equipment will be used exclusively for making boards, you can put another vertical tool instead of the horizontal tool. This will significantly increase sawmill productivity.

I make the fixture for the guide of the circular saw

In order to make the best cuts in wood, the stationary saw has to be equipped with a guide. It will be a full-length bar of the table top, set parallel to the saw blade.

For its fastening I prepare 2 pieces of bar 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 is parallel to the saw blade when it is moved.

The choice of a chainsaw for a home sawmill

The main detail of the installation is the chain saw, and it is necessary to choose it with all due care. You can install a new, just bought saw, as well as a used one, like “Ural” brand. Not only a chainsaw can be used to build a sawmill, but also an electric saw. The only thing you need to remember is that you will be limited in your movements because of the length of the mains cable.

For the correct selection of the saw, it is important to initially understand the intended purpose of the installation. For semi-professional, commercial use, give preference to stationary saws with powerful and productive saws. Domestic use of equipment allows you to choose a less powerful chainsaw, creating your own hands a mobile mini sawmill according to drawings from the Internet.

Design and materials for a stationary saw

Homemade circular saw with your own hands can be made by fixing the hand tool on a stable base. In the simplest version, the device is installed on wooden trestles or on a table assembled from plywood and boards. The tool is fixed at the bottom of the plywood sheet, a cut is made for the toothed disc in the tabletop.

Parameters of the machine design depend on the size of the material to be processed. In accordance with it, the power of the hand tool is selected (800-1200 W or more). To perform a clean cut, it is better to install a model with a speed of 3000-4000 revolutions.

To make the machine will require wood materials, fasteners and tools:

Tools for making a homemade circular saw.

    plywood with a thickness of 20 mm or more;board for stiffeners and legs (50×100 mm);sandpaper, joinery glue and varnish;bolts, self-tapping screws, screw clamps;tape measure, pencil, ruler;electric jigsaw, drill, electric screwdriver.

The height of the table is selected according to the master’s height and is usually about 1 m, the length of the table top depends on the size of the materials to be processed.

Variants of the planer machines with their own hands

Homemade wood rismus machines are used for sanding a large number of elements and giving them an attractive appearance. The design of such equipment includes:

  • Table with frame for the machine. The tabletop must be perfectly flat and stable to withstand the vibration of the work.
  • Knife shaft. The main part of the construction responsible for the processing of wooden workpieces. Pulley speed should be 4,000 to 7,000 rpm.
  • Bolts for adjustment and device for feeding the workpieces.
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To properly make the equipment, use the drawings of the thicknesser. With his own hands to assemble the design should be strictly on them.

When the preparatory stage is completed, you can move on to the direct assembly, which will take about an hour for a person skilled with the tool:

“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 the high RPM of the saw;
  • The shaft installed in the collector motor on the bearings with honor to withstand the radial load;
  • perfect (cantilevered) mounting of the disk, it enables relatively quick replacement of the cutting tool, so there is no need to disassemble the circular saw.

The main advantage of making this machine is the “native” motor which guarantees maximum performance thanks to the ideal torque, optimal rpm. Other advantages of this solution

  • Relatively simple locking system that makes it possible to dismount the saw quickly in case of great necessity.
  • Powerful motor for long hours of work because of its ability to withstand considerable loads.
  • A normal thermal regime, guaranteed by the forced ventilation of this hand tool.
  • Ability to obtain a sufficient depth of cut using large-diameter discs. 60-75 mm. the value that gives a good chance to make high-quality blanks for various products made at home.

Bed and table top

Modification of manual saw into circular saw machine begins with making table (or case-box) from back side of which later will be fixed electric hand tool in such way that part of cutting edge would protrude over table top surface.

Choose the shape and size of the table based on the size of the future timber. If you plan to do small billets, it will be enough length 1500 mm, width. 600-700 mm. For the manufacture of the bed of the circular saw is suitable steel angle, which has a width of the shelf equal to 25-30 mm. The top and bottom of the structure strengthen the struts made of the same angle or rebar. This option is optimal to provide the frame of the machine with maximum rigidity.

For the tabletop 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 composing the table top do not necessarily have to be of the same size, have a symmetrical arrangement relative to the bed. The main thing that the structure is not at risk of tipping.

In the table top make a notch, designed to extend the blade. The part of the table surface that will be in contact with the cutting tool is often covered with tin, metal sheet (aluminum, steel), textolite or plastic. This solution makes moving the wood as easy as possible.

Modification of saw control

Such operations can be carried out only in one case: if the tool’s warranty period has expired. For ease of control of the circular saw, the contacts of the button and the knob (lever) lead to an external electrical switch that is mounted on the body in a convenient location, but there, where accidental pressing is completely excluded.

If the owner foresees the possibility of removing the hand-held tool from time to time in the future, the contacts are fixed with tape or clamp. The circular saw cord is then plugged into a carrying case with an on-off button.

Guiding ruler

It is necessary for precise cutting of material of different width, that is why this ruler (stop) must be able to move parallel to the cutting edge. Such an element is also made of steel angle. Make slots in the tabletop, in which the ends of the guide are fastened with screws.

A simpler option. a pine board. Its width is 40 mm, its length is 200 mm more than the table’s. First, nuts are pressed into the lower part of the protruding edges, and the screws fix the L-shaped hooks. After installing the board on the tabletop of the circular saw, they are tightened with screws, thanks to them, the hooks are raised and securely fasten the ruler. Just as easily it can be moved to any place.

Making a saw with your own hands

Considering all the nuances, the size and pitch of the teeth on the cutting element, you can proceed to the self-assembly of the band saw at home. You can save a lot of money on this, but you will still need to buy some parts and materials to assemble the work table or the device that drives the mechanism.

Assembling a band saw for wood with their own hands according to the drawings includes the following elements:

  • belt pulley;
  • cutting element for the band saw;
  • V-belt type A710;
  • supporting rod;
  • guides;
  • pulleys;
  • electric motor with a choice of power depending on the amount of work to be done;
  • belt drive;
  • bracket;
  • two M12 type nuts (2 pcs.);
  • V-belt;
  • guide;
  • damper;
  • supporting rod;
  • upper support;
  • slider
  • adjusting screw;
  • top belt drive.

Some parts can easily be replaced with improvised materials, which almost anyone has in the garage. Other elements of the machine require the purchase of production models. For example, the electric motor cannot be assembled by your own hands, and the equipment from a washing machine or similar equipment is not suitable due to insufficient power.

Design and assembly of the machine

There is nothing complicated about assembling a homemade band saw with your own hands. Here you need to study all the nuances and prepare the necessary material. The main part of the joinery machine is a working table, on which the processing of wood, metal, stone or synthetic. Design provides for circular motion of the cutting element, which affects the workpiece and is secured by two pulleys.

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It is worth noting right away that the drawings of homemade bandsaw for wood will be suitable only if there is a room of appropriate dimensions. Worktop and bed with the installed unit has an impressive size, which simply will not fit into a small room. This kind of equipment is used for breaking big logs, but the mini-machine is good for small workpieces as well.

At the first stage of the work are made in a special program drawings band sawmill with their own hands. There is a mass of ready-made schemes for assembling this unit, but they may require some changes depending on the size of the room, the amount of work and material to be processed.

Bed and pulley block

The frame of the frame is the bearing part, which holds much of the weight of the whole structure. The stress caused by vibration during the work is several times higher, which is why the basement must be made of metal profiles that must be welded together. For medium and small sized machines, in the absence of metal profiles wood is suitable, but it must be a solid board with a width of 20mm and not chipboard or plywood.

The boards are joined in such a way that the layers are connected at the intersection of the fibers. For additional strengthening of the frame assembled from bars, self-tapping screws, special glue, fasteners and any other connection methods are used. As a result, the entire structure must comply with the functions of the damper, which dampens the jerks and vibrations received during the operation of the cutting element. For this the frame must be rigid and resilient.

Another important detail is the upper pulley block, which keeps the web in tension. The wheel shaft is mounted into an insert located on the inside of the frame. The axle is adjusted by means of two threaded rods that are nutted into the wood material.

The upper (end) part of the frame is equipped with a special screw mechanism which is responsible for the vertical movement on the guide rail. The whole structure is strengthened by adding washers that are welded to the surface. A flange is provided on the back side, on which the shaft is fixed for the boring.

Features of the table top and the pulley

The pulley will require several sheets of plywood, which are glued together, and then a hole is made in them for the bearings. The plywood wheels should be about 30 mm thick. The sawmill must be stable and therefore there must be an additional bearing secured to the clutch. This can be done by placing a washer on the shaft on the inside and securing the flange on the opposite side.

Next, the wheels should be shaped into a barrel and cover the surface with a bicycle tube or similar material. This will help make the movement of the belt smooth and center it independently during work.

If the bearing is not properly secured, then there is a problem with the wheel, which is constantly hitting the plane during operation. From this the cutting element begins to slip and go sideways, which eventually leads to damage to the material to be processed. To avoid such situations, the bearing is installed behind the perpendicularity of the shaft.

Assembled bandsaw with your own hands on metal, wood or stone requires installation of the table top on the bollard base. The motor and the starter are placed inside the washer. They are responsible for the movement of the webbing, its speed, and its running time. For making such a table plywood is often used, which is additionally covered with textolite.

The load on the tabletop is minimal, so this material is quite enough to work. To make it easier to work, the machine is equipped with a variety of functions. For example, the table top is equipped with a swivel mechanism for convenient sawing the workpiece at a given angle. Parallel stop or installing a roller system will add horizontal movement to the table, which greatly speeds up the processing.

Setting up the bandsaw

Efficient and high-quality work of the joinery depends directly on the setting of the equipment. There is a scheme for setting up the machine. First set the wheels parallel to one another. Then the Teflon washers are installed, which are necessary to prevent vertical misalignment.

The first time you start without guides. At this stage they check the smooth start and the cleanness of the motor, and then a test cut with the blade, but with minimum loads is carried out. To work with an increased load use a unit with guiding belts. Such a design consists of two halves, which are installed along the line of the cutting blade.

In the past, craftsmen with their own hands made not only machines, but also a cutting blade. To close the band saw unit into a ring by yourself is difficult and requires at least some initial experience in assembling the machine. The manual method is carried out and sharpening according to the template. All this can be done by yourself, saving your money, but the modern market is simply full of all kinds of devices and parts that improve the quality of processing materials or make the equipment multifunctional. The main thing in this case. remember about safety, because the production models or homemade represent a great danger to human health.

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