How to make a circular with your own hands at home

How can you make a circular with your own hands?

Today, you can often find homemade circular saws. A do-it-yourself circular can be made if the master has at least minimal skills in working with metal. For the manufacture of the structure, you will also need some fixtures. All work must be done carefully.

Stationary circular saw diagram.

It is advisable to make such a device yourself if any of the following materials are available: pieces of a corner made of steel, a rectangular shaped pipe, an engine or an angle grinder. If there is no motor, it can be purchased on the construction market.

Manual circular design

You can easily do a manual circular with your own hands if an angle grinder is available. You will need to make the following simple tools: slide stop and axle handle.

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  • Metal corner.
  • Washers.
  • Bolts.
  • Nuts.
  • Metal strip.
  • angle grinder.
  • Metal pipe or rod.

Making a stop and preparing the necessary holes

Circular saw T-stop diagram.

The slide stop is made from several pieces of a small metal corner, which are located on either side of the working element. It should be noted that the working element is a disc with teeth, which is used instead of an abrasive wheel. The gap on each side should be approximately 3-4 mm. The horizontal edges of the corners will need to be rounded at the bottom so that they do not cling to the workpiece being cut. The corners will need to be cross-linked at the front and back. For this, it is best to use bolts with nuts, a gap can be made using a package of washers.

You will need to put on a clamp made of a metal strip on the tool body. The clamping screw of the clamp should be located at the bottom of the structure. You will need to firmly secure a double-folded strip of sheet metal or galvanized steel with a hole for the rear stop bolt for sliding. The stop must be fixed at the rear of the structure. The clamp with the rear stop can be a single structure, however, the thickness of the metal strip in this case should be approximately 1-1.5 mm. By moving the washers that provide the gap, you can achieve the same gaps between the working element and the side parts of the stop.

In the gearbox housing of the tool, you will need to drill 2-4 threaded holes for small fasteners. The first step is to disassemble the gearbox and identify the places where it is possible to drill. The holes are designed to be able to fix the homemade axle handle. If a standard side handle of an angle grinder is used, it will be quite difficult to make an even cut even for a skilled worker.

Making a handle and adjusting bar

The axial handle is made from a pipe or rod in the form of a horn, which is directed upwards. In this case, a cross brace with a small width can also be used. The ends with which it will be fixed to the gearbox do not need to be splashed. In these parts, you will need to drill holes for fasteners. If the mounting ends splash, the handle will bend from the effort during operation.

If the handle looks like a horn, then the far part of it must be splashed in a horizontal plane and a hole must be drilled in it for an axis of 4-5 mm with a margin. If the handle is a bracket, then in the holes that are located in the gearbox, you will need to install a piece of a rod or tube sticking out forward. The end of the element must be splashed and a hole drilled in it. There should be a small distance between the rod and the bracket. approximately 100 mm.

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Next, you need to take a piece of a 4-5 mm steel rod, which will be used as an adjusting rod. One part of it must be bent in the form of a loop, slightly splashed and drilled a hole for the front stop bolt. Substituting washers on the front of the stop, you need to achieve a uniform slot width along the entire length of the structure. If a 6 mm rod is used, then you will need to prepare several washers of small thickness.

The back of the rod needs to be threaded. The element will fit into the hole in the handle. One nut must first be screwed onto it, and upon completion of assembly, the second. You will need to loosen and tighten the nuts in turn so that you can adjust the cutting depth. At this stage, the manual circular will be ready for use.

Tabletop small circular

The hand-held circular can be easily converted into a small tabletop design.

To do this, you need to make a U-shaped bed from a pipe or rod of 15-20 mm and attach a lever. The lower part of the bed must be bent along the cutting direction to horizontal, and then fixed to the table with self-tapping screws. To make the structure stable, slopes can be additionally installed.

On the horizontal cross member, you will need to put on a rotating lever from a T-shaped pipe.

Circular saw performance check diagram.

The transverse part of the element will need to be cut into two parts. After the structure is installed, the elements will need to be fastened with clamps. To the end of the vertical part with a clamp, you need to tighten the hand saw that was made.

A similar design can also be used as a cutting device, for which you need to install a standard cut-off wheel in an angle grinder. However, in this case, the thickness of the cut will not exceed 70-80 mm, everything will depend on the diameter of the working element. To be able to process thick lumber, you need a full-fledged circular saw.

Complete stationary circular

It is possible to make circulars of this type only if you have a design diagram. The difference between a stationary and table circular is the height of the bed. A diagram of a structure of this type is shown in Fig. one.

The first piece to make is the table. It is covered with tin or galvanized sheet. The wood will rub against wood or plastic, resulting in a small hole. In this case, it will not be possible to make a high-quality cut. Transverse table joints are made of 70-80 mm metal corner.

The working element should not protrude more than 1/3 of the diameter above the table base. otherwise the saw will be dangerous. Therefore, if it is necessary to cut a 100 mm beam, then the disc diameter must be 350 mm or more. To drive such a disk, a motor with a power of 1 kW or more is required.

The first step is to compare the power of the purchased engine with personal needs. For blanks of 150 mm and more, it is quite difficult to make a circular yourself.

A high-quality adjustable stop can be made from a piece of 70-80 mm corner, its length should be 350-400 mm longer than the table length. One of the shelves will need to be cut on both sides so that the remainder is equal to the length of the table. The backs need to be bent down. In the lower shelves, you will need to drill holes for the thread of the fasteners. After that, you will need to put a stop on the table and fix it in the required position with bolts. The stop is set according to a template that is laid between it and the tool disk.

The most critical unit is the shaft. It is recommended to use a ready-made element with a seat for the disc. It can be purchased in the construction market.

You will need to use self-installed ball bearings. Trunnions with bearings should be with covers that can protect against sawdust.

It is recommended to use a V-belt drive. The engine will fit from an old washing machine. Capacitors can be paper or oil paper. Other elements will not be able to withstand the reactive power that circulates in the chain.

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It is quite easy to make a circular yourself if you know the technology and have all the necessary elements in stock.

How to make a stationary or manual circular with your own hands

A hand-made circular saw is an excellent tool that allows you to solve a large number of household and other tasks. In fact, it is not difficult to make this device on your own, even in that situation, if you do not have any special skills, the most important thing is to understand at least a little the principle of processing metal alloys.

The materials you need for the job can be found in your home workshop or garage. So, a circular saw from a circular saw with your own hands is made from the following elements:

  • corner of strong steel;
  • rectangular shaped tube;
  • engine.

The finished circular saw can be positioned on a workbench. If you do not have one, you will have to make the table yourself. The engine can be taken from an old walk-behind tractor or washing machine.

Circular from an angle grinder

If you have your own “angle grinder” that’s very good. To create a “circular“, you need to make an axial handle and a sliding stop to the unit. The design of the sliding stop includes a pair of steel angle pieces placed on the sides of the saw blade. With the help of nuts and bolts, they are connected by a transverse bundle, and the gap between the working part and the sidewalls of the structure will be provided with washers.

On the “angle grinder”, it is necessary to pre-tighten the band clamp made of metal with a screw tie down. Then you need to attach the double-folded metal strip to the holes for the sliding stop. The stand and clamp can be combined, but in this situation the metal strip will be too thick.

Then, in the gearbox of the future tool, you will need to make several holes for the bolts. For this purpose, the body is disassembled, and the points where drilling will take place are indicated. With the help of the holes made, the axial handle is fixed, because the “standard” handle will not allow you to make a good cut, even if the master has very strong hands.

The handle is created from a metal tube or rod. Designs can be shaped like horns or staples. The ends of the element with which it will be attached to the gearbox must be provided with holes for installing fasteners.

You also need to make a barbell that will regulate the process. For this purpose, you need to take a piece of metal rod, make a loop from one end of it, rivet it slightly and make a hole for the front stop bolt.

At the other end of the rod, you need to make a thread that will allow you to connect it to the handle. In advance, one strong nut should be screwed onto this thread, and after the structure is assembled, the second. By lowering and pulling them, you can adjust the cutting depth. By the way, if you use a drill instead of an angle grinder, you can make a similar tool.

Thus, you can independently make a good circular saw out of an ordinary angle grinder, with which you can cut various materials.

Compact benchtop machine

The above talked about how to assemble a hand circular. Now we will tell you how to turn this device into a stationary one. This process involves the manufacture of a U-shaped bed from a pipe, as well as the installation of a transverse arm. The lower ends of the structure should bend horizontally in the direction of the cut. They are bolted to the table. Stability is ensured by additional supports.

The lever mobility is ensured by cutting the horizontal segment into two identical parts, which are fixed to each other with clamps. The saw blade is attached to the vertical element of the bed with clamps.

Stationary installation

A machine similar to factory models needs a competent attitude during the assembly process, so you need to take care of all the little things in advance. The desktop version of the “circular” differs from the stationary only in the height of the bed, which is determined by the peculiarities of work and the size of future workpieces. One-time processing can also be done using an ordinary table saw, which after work can be easily removed to the pantry or shed. But a master who constantly deals with wood will need a stationary installation. Therefore, he needs to make a table for a circular saw with his own hands.

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The circular machine has the following advantages:

  • Such equipment allows you to make better and deeper cuts.
  • The machine is much more convenient than manual equipment.

From the foregoing, we can conclude that circular saws, made independently, have a completely understandable and simple design, and the drawings that can be found on the vastness of the World Wide Web will greatly simplify the process of assembling equipment. Before making your own “circular”, you should separately consider all the necessary elements in order to understand the nuances of the functioning and installation of homemade equipment.

Simple circular from an angle grinder or circular saw

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

Plane Slip Element

This element is made of Laminated Chipboard due to the fact that the surface is laminated and smoother. this reduces friction (improves sliding), as well as denser and stronger. more durable.

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At the stage of forming the blanks, we have already cut them to size, it remains only to refine the edges. This is done with an edging tape.

Edging technology Chipboard is simple (you can even glue it with an iron!) And understandable.

Recommendations for simplifying the assembly process

To adjust the belt tension, the motor must be positioned so that it can be moved. The easiest way to achieve this is by creating slots larger than the motor mounting bolts require. In this case, the expansion of the holes should be carried out in the direction of belt tension.

If you completely follow the drawing, you will need to make a more complex belt tensioning mechanism. The process will be carried out by tightening the platform with an electric motor using pins and fixing it with locking bolts in the desired position (in the drawing, these structural elements are indicated by the number 10).

The whole structure and assembly process can be greatly simplified if you make a circular from a circular saw. In this case, there is no need to install a number of parts (motor, disk, shaft, belt, starter). But the capabilities of the created model will be limited by the power of the used tool.

In any case, a homemade circular must be grounded. It is also recommended to install a residual current device or differential circuit breaker in the panel. These measures will protect against electric shock if the machine body is energized, for example, due to a breakdown in the insulation of wires. It is better to choose accessories for the electrical part of the circular machine so that they are suitable for repair and easy to maintain. Free access to equipment assemblies will help to replace failed parts without any problems.

Assembling the transverse and longitudinal parts

First you need to mount the substrate (longitudinal element) with the upper transverse clamping bar.

Right here HIGHLY. it is important to maintain an angle of 90ยบ, since it will determine the parallelism of the guide with the plane of the saw blade.

Then we install the longitudinal base on the substrate.

Circular production

Eccentric installation

The eccentric is installed between two vertical elements on the longitudinal part.

In the eccentric itself, you need to place a metal tube (future sleeve) with an inner diameter of 6-10 mm.

In addition to the bushings on the eccentric itself, you need to make similar bushings on the vertical elements, although, as an option (worse), you can use enlarged washers.

Additionally, a thrust bar must be installed for better clamping.

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