DIY circular saw

Construction site

The primary processing of wood materials often consists of cutting them. For execution, you can use several types of tools. from hand-held to electrical models. The most effective is a stationary circular saw, which can be made by hand.

Circular saw table design

The main component of the future design is a hand-made table. It will house the power unit, cutting tool, control unit and additional components to get the job done.

There are two fundamentally different schemes for designing a table. In the first case, it is designed to work with a hand saw. The main task of the support frame is to fix the workpiece and the ability to change the direction of the cuts. Most often, wooden components are used to make a table with their own hands. sheets of chipboard, slats and timber.

The sawmill is one of the varieties of circular saws. The difference lies in the bottom position of the disc. In this case, the table functions as a bed. It houses the power unit, there is a disk mounting block, as well as a control system.

During design, the following points must be taken into account:

  • electric motor power. For housework, it is enough to choose a model with a specific power of up to 800 W;
  • cutting depth. Depends on the geometric parameters of the disk;
  • rotation frequency. To form an even color, this characteristic must be at least 1600 rpm;
  • location of the control unit. It should be as far away from the disk as possible.

The dimensions of a homemade design depend on the size of the parts being processed. For the manufacture of a manual sawmill, it is recommended to use a metal sheet as a tabletop. Additionally, stiffeners are mounted at its base.

When choosing a factory saw model for completing a do-it-yourself table, you should provide for the possibility of mounting at the bottom of the tabletop. To do this, you will need to make an additional adapter mounting block.

Assembling a complex machine

There is an option with a more complex and heavier structure. She will definitely cope with cutting pipes. At the same time, a self-made installation does not require the use of a circular as a component of the machine. But for certain stages of work, it is better to have a circular on hand.

Depending on the components you choose, you can get a higher power machine. To assemble the machine with your own hands, you will need:

  • Electric motor with a power of about 900 W. If you have to cut pipes regularly, you can choose a more powerful electric motor;
  • Metal sheet;
  • Metal corners;
  • Channel;
  • Hinge groups;
  • angle grinder;
  • Welding device;
  • File;
  • Spring of impressive power.

When everything you need is assembled at the workplace, you can start assembling the miter saw with your own hands.

  • A homemade bed can be made by hand using adjustable supports, metal corners and bed racks.
  • A sheet of durable metal acts as a working surface. In this table-sheet you need to make holes and process them with a file.
  • To weld a pendulum rack for a future machine, use channels and a welding machine. The structure is installed on a metal sheet. Approximate rack height. 80 centimeters.
  • The support for the electric motor is made of a metal sheet in the form of a fixed plate. Be sure to install the stand on the hinges.
  • The stabilizer of the electric motor of the miter saw is a powerful spring. If you managed to find one, it is quite possible to refuse from belts and a swingarm.
  • Using the eyebolt, you can tension and adjust the belts. The pendulum can be made of metal to make the structure reliable, durable.
  • Select the disc of the required diameter with the operating tool. For domestic purposes, a saw blade with a diameter of 400-420 millimeters is usually sufficient.
  • Be sure to provide for the presence of protective covers, since the assembly of such a machine is accompanied by a certain degree of danger.

Choosing the option of assembling the machine with your own hands, and not buying a factory trimming machine, you need to understand that there will be a rather serious difference between them in quality, accuracy and error in processing wood, pipes, metal and other products.

Let’s start assembling

  • We cut out a rectangular sheet of plywood and make a long cut on it, along which your trimming will ride;
  • From above we fasten two guides, for example, from an aluminum corner, to the width of the working plane of the circular itself;
  • From the bottom to the plywood sheet you need to screw two supports with a height equal to the cutting depth of your saw (5.3 cm).

As a result, we get a guide along which the circular will walk. Depending on how we fix it on the table with such a simple mechanism, we can make an accurate cut at any angle. The simplest design option is ready.

What if we want our miter saw to be more functional at work and look like a factory miter saw? In this case, you will have to show more ingenuity.

  • First, you need to make a bracket and a stand on which the circular will be fixed. Chipboard (27 mm) is an excellent raw material for such a mechanism. With the help of self-tapping screws and aluminum corners, you will get a very decent top end. And the springs fixed on top can make the work on such a saw more convenient;
  • Secondly, you need to fix the tripod itself on a movable pivoting footboard, make a pendulum saw, thanks to which we will eventually be able to change the facing angle.

As for the trimming itself, everything is said about the assembly. However, if we decided to make a saw that looks like a factory saw, then it will be difficult to do without a table.

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Circular saw design

General scheme of a stationary circular saw

At the first stage, you should understand the design features, determine the optimal manufacturing scheme. It directly depends on the characteristics of the work performed, the dimensions of the workpiece, the type of wood. Only after this can a circular saw be made with your own hands.

The main component of the saw is the blade, on the end surface of which the cutting teeth are located. They can differ not only in geometric dimensions, but also in the angle of inclination relative to the plane of the disk. To carry out cuts, an electric motor is provided in the structure. It can be connected to the disc directly (through the shaft) or by means of a propulsion torque transmission system. This tool is designed to perform longitudinal and cross cuts, in some models it is possible to make angular, relative to the plane of the workpiece.

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Before making a circular saw with your own hands, you should choose the processing depth. To do this, you need to familiarize yourself with the equipment classification:

  • small. from 40 to 46 mm;
  • medium. from 55 to 55 mm;
  • large. from 65 to 70 mm;
  • professional. from 65 to 140 mm.

For household chores, it is enough to choose a model with a low or medium cutting depth. If complex material processing is required, a hand-held circular saw is required. To make vertical cuts, you can make a homemade sawmill.

For woodworking, it is necessary to choose discs with a positive sharpening angle. Otherwise, the wood fibers will not be cut, but torn.

This design has two main disadvantages:

  • To adjust the accuracy of sawing wood with a broaching machine, you need to use wood trimmings. After that, the traction can be firmly fixed and work normally;
  • Such a self-made installation with a broach when cutting pipes and working on metal makes a lot of noise, which can negatively affect at least the mood of your neighbors.

A miter saw consists of several essential elements

Let’s get to the heart of the matter: you have a circular in stock, and you are assembling a homemade miter saw. The first three points are already present in the circular itself, and the fourth may not be needed if you skillfully assemble a guide rail for the saw.

Shelf design

Fragments of chipboard or thick plywood should be fastened to the table surface relative to the slot with self-tapping screws, increasing them, screwing to each other, to the previously measured level of the circular saw positioning height.

It should be noted that at the very last level a chipboard layer will go, which will form a shelf for the circular saw to move. So, while increasing the height, you should remember about the thickness of the Chipboard of the last layer.

circular

The shelf for the circular movement consists of two parts, symmetrically located relative to the mowing line, the cut for free movement of the disc. In fact, there should be 2 “bridges” set parallel to each other across the space for the saw blade and the right edge of the table at the very right side of this table.

Preparation of the base

The base of the circular facing is a rectangular sheet of thick plywood or chipboard, not deformed. In the future, a shelf for the movement of the circular saw will be rigidly attached to the base.

In the base sheet (in the table), you need to make a slot for free passage of the saw blade. The blade must completely cut the workpiece positioned on the table surface, so the saw teeth must go deeper than the table surface, but the blade must rotate freely. It is even recommended to form a table from two sheets of chipboard or plywood, attached to each other flat: then in the top sheet it will be necessary to make a through transverse slot for free movement of the saw blade.

Circular saw design

General scheme of a stationary circular saw

At the first stage, you should understand the design features, determine the optimal manufacturing scheme. It directly depends on the characteristics of the work performed, the dimensions of the workpiece, the type of wood. Only after this can a circular saw be made with your own hands.

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The main component of the saw is the blade, on the end surface of which the cutting teeth are located. They can differ not only in geometric dimensions, but also in the angle of inclination relative to the plane of the disk. To carry out cuts, an electric motor is provided in the structure. It can be connected to the disc directly (through the shaft) or by means of a propulsion torque transmission system. This tool is designed to perform longitudinal and cross cuts, in some models it is possible to make angular cuts relative to the plane of the workpiece.

How to Make an Automatic Circular Saw Sliding Guide

Before making a circular saw with your own hands, you should choose the processing depth. To do this, you need to familiarize yourself with the equipment classification:

  • small. from 40 to 46 mm;
  • medium. from 55 to 55 mm;
  • large. from 65 to 70 mm;
  • professional. from 65 to 140 mm.

For household chores, it is enough to choose a model with a low or medium cutting depth. If complex material processing is required, a hand-held circular saw is required. To make vertical cuts, you can make a homemade sawmill.

Turning a hand-held circular into a tabletop

To convert a homemade hand-held circular into a tabletop one, you need a stable, sturdy table. It will be not only convenient but also safe to work on it. The basic procedure consists of the following steps:

  • Bend a metal rod with a diameter of 1.5. 2 cm in the shape of the letter “P”.
  • Bend the lower part, flatten it, attach it to the table in a reliable way.
  • Two-piece hollow metal pipe weld T-arm.
  • Change the transverse part so that it can be easily put on the crossbar of the main part of the structure.
  • Fasten the metal structure with clamps.
  • Attach a hand circular to the end of the installed arm.

If you equip an angle grinder with a conventional cut-off wheel, then the device can be used as a cut-off structure. But the cutting depth will be no more than 8 cm. The table circular is not suitable for processing thick materials or ripping. In this case, a circular saw will be optimal, which can also be made independently.

Determining the height of the shelf for lateral movement

If the person working on the machine is right-handed, then the shelf for the circular saw should be located on the right edge of the table in order to be able to fix the workpiece on the table.

circular

You should adjust the protrusion on the circular saw to the maximum and measure at what height above the table you need to position the shelf for the circular movement of the circular so that the teeth of its saw blade do not touch the table. This measurement will actually determine the maximum thickness of the workpieces.

Main selection criteria

power. Affects performance and speed of work. With its increase, the weight and cost of the tool grows. Household cutters consume less energy than professional cutters; disc size. The depth and speed of the cut depends on it. Also find out if there are removable discs on the free sale for the selected tool model; cutting parameters. Angle, width and depth. The saw should cut the workpieces at the angle required for your purposes, preferably in both directions. The manufacturer also indicates the maximum depth of cut when working at an angle of 45 and 90 degrees to the surface. The function of limiting the cutting depth is important. It is used when grooving and processing workpieces by thickness; Setting the angle of the presence of a broach horizontally. Allows you to increase the kerf width by moving the cutting part in the horizontal plane. A wide enough workpiece can be cut in one pass. Affects the cleanliness of the cut and makes it possible to work with hard materials. The number of revolutions from 4000 and more is a very good indicator. Engine type: collector. It is necessary to check the armature regularly, but such a motor has more torque; asynchronous. Quieter and longer; transmission type: cogged. No slippage under heavy loads; belt-operated. It makes less noise and dampens vibration, but the belt breaks more often than the teeth of the gears wear out; straight. There is no gearbox, fewer rubbing parts, but lower torque; swing system design. It should: have clamps for frequently used corners and clamps; pivot at different angles. Specify the angles; adjust without backlash; Swivel system with a safety clamp. The miter saw must have components that ensure safe use: a system that automatically closes the working disc with a protective cover when lowering onto the workpiece; Protective sheath for the splitting knife. Protects against disc seizure; soft start. The engine gradually picks up speed, you need to let it accelerate and wait a few seconds. Without this option, exceeding inrush currents knocks out the automatic switches and quickly destroys the motor and gearbox of the tool; electrodynamic brake. It stops the working disc quickly and smoothly; blocking accidental start-up with a latch that prevents the shaft from rotating. Convenient when replacing discs; bag-shaped dust collector. Attached to a special pipe. You can connect a vacuum cleaner to it.

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Aligning workpiece guides

It should be a strip of chipboard or thick plywood, only here it is no less than 10 cm wide, since it will have a much greater length. the guide should be 20% longer than the table so that it is always possible to fix it with a clamp in two places It is installed closer to the front edge of the table at the desired angle to the saw blade slot, and secured with clamps.

It is not necessary to fix the guide on self-tapping screws at all, since in this case it will be impossible to adjust the cutting angle if necessary. The guide for the blanks, of course, should be one, since the second simply cannot be fixed with a clamp in 2 places. When working on such a facing, the workpiece must be tightly pressed against the previously fixed guide with one hand, and with the other (right) cut the workpiece with a circular saw.

There are several types of miter saws depending on the way the product is processed.

  • Saw with a broach. The cross cut with a broach is endowed with a specialized mechanism for moving the disc on a horizontal surface and is practiced for sawing wide products. It is installed on two slats located in the same direction, whereby it moves freely within the boundaries.
  • Saw without broach. A regular saw is not endowed with such an option.
  • Combined fixture. The combined tool can be used both for facing and as a sawing unit. Such mixed modifications are equipped with both a disc and a wedging knife, at the same time, they are immediately supplemented with a specialized table.

Another classification distributes the miter saws by gear type.

  • The toothed gear prevents the drive from slipping during the processing of wood blanks, which often happens when trimming is performed at full power.
  • With a belt drive, slight slip is not excluded, but this is not accompanied by sounds. In addition, the belt drive is vibration-free, which contributes to a longer service life.
  • Universal trimming, which is also called stationary, will fit both for dissolving boards and for finishing ends. Basically, this type of saw blade has a diameter of 25 cm. The very small device is attached to the table using specialized ingredients. The pendulum miter saw is often equipped with a laser cutting line indicator. This attachment is characterized by high power and the required working depth.
  • The miter saw is available for both professional use and for everyday use. The home appliance has a simple design, a power balancing from 1000 to 1200 watts, and an average stability with respect to intensive use. Household saws cannot be used non-stop as they regularly need to take breaks and cool the engine. At the same time, home tools are perfectly handled with simple everyday issues.

Miter saw for wood. making from a circular do-it-yourself

For transverse sawing at different angles of wooden blanks, when accurate joining of several elements is required, a special tool is used. A do-it-yourself miter saw is made on the basis of the existing equipment. from a hand circular, an angle grinder. And when installing discs of a certain type, a home-made design can be used to cut a light metal-plastic profile, pipes, which will expand its scope.

The design is simple and available for making at home. The body of the sawing machine is assembled from wood or metal. A base is constructed from plywood sheets (chipboard), on which a vertical stand is installed, after having cut holes in it for fixing a circular. The pendulum-type mechanism is made from a board and is fixed to the support with a long bolt.

Having prepared a corner or a metal rod, it is screwed on top of the pendulum, trying to make the end protrude. Take the spring. With one side, it is fixed to the back of the corner, and the other to the vertical rack. The tension is selected experimentally, but it should be sufficient to freely support the hand-held circular saw.

Having disconnected the handle from the tool, it is fixed on the pendulum in the prepared hole. The cables are laid in the grooves provided for this and the voltage is connected. A small slot is made in the tabletop and side stops are fixed to it at right angles. If you make them rotary, then you can cut the workpieces at a given angle. The circular saw is assembled, it remains to test it in action. Using the available drawings, it is easy to make any, even more complex tool.

For the convenience of work, a cross-cut machine should be made. It is desirable to have a mobile structure if you have to move with it to another place or directly to the construction site. Therefore, the bed is made collapsible, for which the table top is attached to the legs with self-tapping screws.

To make a workbench, you need to do the following:

  • Prepare the upper frame. It is assembled from a wooden beam with dimensions of 40×40. Legs made of a similar material are screwed in with self-tapping screws and spacers are installed for their greater stability. Or the joints are reinforced with metal corners.
  • The table top is made from the boards. Its width should be 10 cm longer than the length of the miter saw, and the length should be equal to the width multiplied by 3.
  • Taking sheets of plywood (Particleboard, Fiberboard), prepare and fix improvised tables, trying to position their surface on the same level with the swivel mechanism.
  • Install end trimming equipment.

Such wood trimming will be in demand in your workshop or when carrying out various construction work, in which you cannot do without woodworking.

If you need to make a machine with a broach, then for this they take the shock absorbers of the front pillars of the car. Preferably a passenger car, because they are too massive from a truck. You can buy them at any car disassembly point. Before installing the shock absorbers, in order to facilitate the stroke of the rod, the oil is drained and “air” holes are made in the body.

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For comfortable operation, it is recommended to connect a soft start system. It will reduce the load on the structure during the start jerk and regulate the number of revolutions.

The angle grinder miter saw is one of the common models. The advantage of this design is that the angle grinder can be removed and, by changing the disc, used for its intended purpose. for metal cutting. The simplest scheme allows you to saw boards at an angle of 90 degrees.

  • First, make the support frame from a metal sheet framed by a corner. A vertical rack made of a metal profile is welded (bolted) to it.
  • Brackets for attaching an angle grinder are fixed to the pipe segment, which is wrapped in a casing made of any available material. The main condition is a secure fixation of the sander.
  • The pipe is fastened to the post with a conventional bolt connection. For holding in an upright position, limiters or a self-tightening device are installed.
  • Having fastened the angle grinder, a cut is made in the bed for the entire diameter of the disc so that the cut of the workpiece is complete.
  • The side stop for changing the position of the workpieces is made swivel. To facilitate the selection of the desired angle, the marking in degrees will allow.

With a broach

This device is considered the most versatile, since the saw can be displaced not only around the axis, but also along the cut along a straight mowing line.

Varieties of miter saws

There are several types of miter saws (popularly also called “miter saws”). Let’s get acquainted with these varieties.

How to make a miter saw from a circular do-it-yourself?

A miter saw is a device that every builder needs to take “into service”. However, it is no secret that a high-quality professional tool on the construction market is quite expensive. That is why those who want to save material resources, as well as show their skills, should try to make a miter saw with their own hands. The starting material for this will be a circular saw.

Let’s start assembling

  • We cut out a rectangular sheet of plywood and make a long cut on it, along which your trimming will ride;
  • From above we fasten two guides, for example, from an aluminum corner, to the width of the working plane of the circular itself;
  • From the bottom to the plywood sheet you need to screw two supports with a height equal to the cutting depth of your saw (5.3 cm).

As a result, we get a guide along which the circular will walk. Depending on how we fix it on the table with such a simple mechanism, we can make an accurate cut at any angle. The simplest design option is ready.

What if we want our miter saw to be more functional at work and look like a factory miter saw? In this case, you will have to show more ingenuity.

  • First, you need to make a bracket and a stand on which the circular will be fixed. Chipboard (27 mm) is an excellent raw material for such a mechanism. With the help of self-tapping screws and aluminum corners, you will get a very decent top end. And the springs fixed on top can make the work on such a saw more convenient;
  • Secondly, you need to fix the tripod itself on a movable pivoting footboard, make a pendulum saw, thanks to which we will eventually be able to change the facing angle.

Caution! From what material you choose for the stand and tripod, how securely you attach them to the footboard, not only the quality of work and functionality of the trimmer will depend, but also your personal safety. No wonder they say that if a carpenter is experienced, then he is sure to be without a finger

Fasten the circular as securely as possible! Safety first!

As for the trimming itself, everything is said about the assembly. However, if we decided to make a saw that looks like a factory saw, then it will be difficult to do without a table.

Advantages and disadvantages of a homemade device

The first and most important benefit of a homemade miter saw is the significant financial savings. So, buying a ready-made tool will cost you quite a lot (average), and making a tool with your own hands from a material point of view is available to almost everyone.

Often, the available tools on the farm are used as starting materials for making a miter saw with their own hands. It should be noted that such materials are not always of high quality. That is why the life and quality of service of a homemade device can be very short and low.

For more on how to make a miter saw from a circular saw, see the video below.

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The difference between a miter saw and a circular saw

The main difference between a homemade miter saw is its relative cheapness.

It can be built from existing scrap Chipboard or OSB.

In addition, thick plywood is also suitable, and in certain cases, textolite.

In addition, homemade trims have the following distinctive features:

  • the machine is built, as a rule, for the existing specific need for cutting parts of a certain dimension. Sometimes it is these dimensions that cannot be processed on commercially available machines;
  • the bed of a homemade machine is made of wooden plates or even from scraps of thick and wide boards. Of course, you can build a frame from steel plates and even from a composite, for example, a frame. from a steel profile, and the table itself. already from a chipboard. But in any case, this will be more expensive and more difficult, because you will have to deal with more expensive metal, and secondly, you need to work with metal welding, and then work with Chipboard.

A homemade miter saw, of course, will be less technologically advanced than a purchased factory-made one. But often no one wants the perfect result. And here the construction of a homemade trimming is just such an option.

For example, if you are going to sheathe the house with clapboard outside, then it would be quite reasonable to carry out trimming in conditions when both the material and the tool will be as free of backlash as possible. In this case, the result will be much more accurate.

A distinctive feature of a homemade miter tool is its relative simplicity, and therefore, it is possible to achieve an almost complete absence of third-party movements of the cutting tool. And all this at no extra cost.

Combined

When using a combined saw, the cutting angle can be changed in 2 directions. The device, like the previous version, contains an additional hinge. In order to change the cutting angle, it must be adjusted and retracted to the side opposite to the place where the drive is mounted.