Circular Saw. How to Assemble Yourself

Circular Saw. How to Assemble Yourself

“I have long dreamed of having a circular saw in home …” – with these or roughly the same words, many posts on social networks begin. And then follows information on how the circular saw was made with their own hands. It is a logical sequence of actions. A skilled craftsman, ready to independently use such a tool, is able to assemble it. How to do this is described in this article.

Scope of homemade circular saw

In the process of building a new home, when wood material is used in large quantities, home-made circular saws will not be enough. And the functionality of such a device will need a wider one. But when performing repairs, the home circular saw machine becomes an indispensable technical assistant.

Quite often, the dimensions of wooden elements are determined directly during the execution of work. The ability to independently provide the process with the necessary materials significantly saves money and time. And often the quality of wooden blanks is guaranteed to be higher.

On a homemade home circular saw, you can dissolve the boards into bars, make planks, battens, trim the workpieces, saw boards from wood materials into fragments of the required size.

Using a home-made circular saw, you can make such types of furniture as a table, shelf, shelving. A similar stationary home tool is applicable when creating wooden sports equipment, manufacturing containers, etc.

When installing a disk with certain technical characteristics on a saw machine, the mechanism can be used as a circular saw for metal. It is allowed to saw soft aluminum and sheets of other types of metal, the thickness of which does not exceed 2 mm. When working with thicker material, the mechanism will overheat, causing an automatic shutdown.

Stationary circular
A firmly fixed table with a saw slot is enough for logging and simple cutting pieces of wood

How to make a circular saw yourself: preparatory stages of work

Before you put an end to the question of the appropriateness of self-made circular saws, you need to personally get acquainted with several similar devices, watch videos on the Internet. During observations and viewing, special attention should be paid to the main elements, parts, and methods of fastening. To understand how to make a circular saw, you need at least theoretical knowledge.

The manufacturing process can be implemented in two ways:

  • a set of elements of the future design in stock, it is only necessary to complete the assembly;
  • constituent circular saws must be purchased.

In the case of the latter option, the task is somewhat more complicated, since parts and mechanisms are most often bought in different places, but they must correspond in terms of technical and functional characteristics.

DIY manufacturing circular diagram
DIY manufacturing circular diagram

Helpful advice! It is only necessary to acquire elements for the future circular saw design after a detailed installation drawing has been developed.

Without a drawing, it is impossible to take into account the dimensions of the elements and pick up a complete set. Quite often, this stage (drawing work) is omitted by home craftsmen due to a lack of performing skills. Doing this is not worth it, since it is quite enough to draw a saw. At a minimum, this will allow us to visualize the future unit. It is extremely important to imagine what will turn out in the end.

Only after a drawing or sketch and all the necessary elements are available, you can proceed directly to the assembly process.

Elements of the construction of a sawing machine for wood

To make a stationary machine for sawing materials at home, you first need to know what structural elements it consists of. Whether it is a do-it-yourself machine made from a manual circular saw tool, a grinder or a tool assembled from disparate elements, the set of basic parts is the same.

The main elements of stationary circular saw installations are:

A table for connecting and securing mechanisms. If the circular saw is powerful and massive, it is better to use a metal table. Chipboard, wood, plywood options are suitable, the main thing is that the surface is smooth.
Shaft. The most critical part. In the manufacture of it separately use a lathe. Dimensions should be calculated accurate, this will avoid beats.
Cover. This element ensures the safe use of the circular saw.
Engine. When using a grinder or circular saw, it is part of a power tool.

Circulars of any fixed type consist of main parts
Circulars of any fixed type consist of main parts

Helpful advice! If the design is supposed to be prefabricated, then when creating a circular saw with your own hands, the engine from the washing machine will be the most successful option.

In the design, the circular saws must necessarily have moving parts of the drives, and a button must be installed in the power supply circuit to stop the engine in emergency situations.

Determination of circular saw parameters

The primary task is to choose the power of the future stationary circular saw. Typically, devices with power up to 850 watts are recommended for home use. If it is not supposed to carry out repairs, but to build, for example, a bathhouse or a summer residence, as a result of which it will be necessary to saw a lot of material, then an engine with a power of 1250 W can be used. A device with a higher rate is not recommended, since such powerful circular saws require not only a solid table stand, but also the fixation of the latter to the floor by fixing or concreting.

An important characteristic is the cutting depth. In home devices, it should not exceed 8 cm. In fact, such an indicator is quite enough for sawing boards, plywood or wood boards.

When making do-it-yourself mini-circular saws or a full-scale sawing design, you must always take into account the speed. If you plan to just cut boards for the manufacture of certain wooden elements, then you can limit yourself to an engine with a low or medium frequency. If you need perfectly smooth and clean cuts, it is better to use a high-speed motor. The optimal indicator for a home power tool is considered to be a frequency of 4500 rpm.

Be sure to consider the height at which the start button will be located. Placement should be convenient for pressing.

Important! The control panel of a home-made circular saw must be accessible.

Manual circular saw as the basis of a homemade design

One of the most popular tools on the basis of which home-made saw structures are created at home is a circular saw (hand circular saw). With this electromechanism, with the help of a round disk, direct cuts are made on wood materials, as well as on soft and thin metal. The tool is quite simple, it has all the basic elements that make it possible to make a circular saw out of a circular saw with your own hands.

circular saw consists of the following parts:

  • electric motor;
  • one or two pens;
  • protective cover;
  • holding platform (for the possibility of setting the disc);
  • propping knife (prevents jamming of the saw blade in the wood).

Manual circular saws stand out among other similar tools and some technical features. For example, it is permissible to change the depth and angle of cut directly during operation. Special opportunities are given by submersible saws. They can perform isolated fragmentary cuts of the required size.

Hand circular saw
Manual circular saw cuts are made straight cuts on wood materials, as well as on soft and thin metal

The accuracy and quality of manual circular sawing depends on the number of teeth on the disc and on the angle of sharpening. With a large number of teeth, the quality is higher, but performance is slightly reduced.

When making circular saws with your own hands from a hand saw, special attention must be paid to engine power. This is very important when intending to carry out significant amounts of work. The total weight of the saw also matters. Lightweight models are suitable for occasional cuts.

Stationary circular saw from manual circular saw

The operational capabilities of a hand-held circular saw significantly increase if it turns into a stationary tool. To understand how to make a stationary circular saw from a manual circular saw, it is first of all necessary to understand the methods of hard fastening a power tool.

As a stand, you can use goats made of metal or wood. It can be either one or two products (if the dimensions are small), interconnected by boards with a thickness of at least 50 mm or bars with a similar cross section. Next, to the top of the stand you need to attach the countertop, which will act as a bed.

For these purposes, it is convenient to use thick plywood (at least 10-12 mm) or two sheets of thinner material joined together, which together will give the same thickness. Chipboard cloths or metal are also suitable. If the metal is thin, it is best to attach it to a wooden base.

A hand saw is installed from below. Previously, in the countertop, the necessary for the advancement of the disk is washed down.

Important! It is necessary to fix the tool so that the saw blade is located strictly parallel to the lines of washing, that is, at the same distance from the sides. Otherwise, it will not be possible to correctly install additional devices and achieve high-quality sawing.

Using the above technical methods, it is possible to make a circular saw from a grinder. But this manual power tool has certain differences, so a slightly different assembly scheme will be required.

Features of the assembly of circular saws with their own hands from a grinder

Not every home workshop can find a circular saw, but almost any owner who does certain work in the household with his own hands has a grinder. To create a stationary saw installation, you will also need a workbench or a special table, the tool will be attached from below, like a circular saw.

But then the assembly process is somewhat more complicated. To make a circular saw tool from a grinder with your own hands, as practice shows, you need to think carefully about the option of attaching a hand tool to the bed. It could be the following way:

  1. A metal band clamp is tensioned on the grinder, the screed of which should be at the bottom.
  2. Double folded strip of metal is attached to the holes for the sliding stop.
  3. Holes are made in the gearbox of the power tool. Previously, the body is disassembled, drilling sites are outlined.
  4. Using the holes made, an additionally manufactured axial handle is attached.
Circular saw assembly features
To make a circular from a grinder, you need to think carefully about the option of attaching the tool to the bed

The handle can be made of a metal tube or rod. The blank must be shaped like a staple. In those places with which it will be attached to the gearbox, it is also necessary to make holes. Big and serious help for making circular saws from a Bulgarian do-it-yourself drawings – drawings. They will allow you to correctly calculate the size and number of elements, to prevent errors in the calculation of fasteners. If it is difficult to carry out the scheme of the future unit on your own, you can use ready-made drawings offered on the Internet.

Possible types for small circular saws

Any stationary circular saw, even home-made, requires a fairly spacious workshop. The space should allow not only to install the unit itself, but also to place the blanks intended for cutting in the right position. If the task is not to dissolve large-sized wood, but just if necessary, you need to independently make a rail or bar for furniture repair, etc., it will be more rational to acquire a desktop circular saw mini-saw.

Such a device can be done with your own hands, using the same principles as when creating stationary machines from a grinder or circular saw. Only the stand will not be the goats, whose support is the floor, but the bed, on which a small table is installed with a fixed hand tool.

Helpful advice! When making circular saws of this type, it is important to take into account the overall height of the structure, that is, the plane on which the material intended for sawing will be located. Overstatement or underreporting will cause significant inconvenience.

small circular saws
The miniature machine is more functional and safer to use.

If you need to create a circular saw mini-saw with your own hands to perform workpieces of very small sizes (aircraft, ship modeling), you can assemble the tool by using a PVC pipe as the body and borrowing the engine from children’s toys. In such a pipe, it is easy to make a hole for the shaft. As a connecting material, you can use a glue gun. Such a circular saw can be powered by both the mains and the battery. To ensure autonomy, it is necessary to provide a special compartment for batteries in the housing.

Carriage for circular saw yourself

The functionality and quality of the stationary circular saw is largely affected by the availability of devices. One of these is the carriage. Performing it at home is completely uncomplicated, but milling and sawing material at an angle of 45 ° will be greatly simplified.

You can make this device for circular saw from a sheet of plywood as follows:

  • cut out plywood a little wider than the circular saw table;
Making a carriage for circular
DIY table saw table can be used as a cutting machine
  • in the lower part, guide bars are attached to it with glue or screws, the distance between which should be equal to the width of the table;
  • from above in a similar way, with the use of screws or glue, fixed thrust bars are fixed.

Using guides, the carriage is fed across the table to the saw blade, which makes a through cut on the fixture. The height of the sides, which should be greater than the protruding saw blade, allows you to maintain the integrity and rigidity of the carriage. If the task is to perform a cut at an angle of 45 °, it is necessary to use an additional bar, which in this device is a removable element. Sawing is done by pressing the workpiece against an angled bar.

So that the plywood surface of the carriage is easily cleaned of sawing waste, it must be varnished in several layers.

circular saw table
Plywood should be slightly wider than the circular table

How to make a shaft for circular saw do it yourself

In the general design of the circular saw, the shaft is the main element forming the machine as a whole. For its manufacture, you will need a steel round log of grade 45. But you can only do this important part on your own only if you have your own lathe or you can access it. The diameter of the workpiece should correspond to the dimensions of the saw blades that are supposed to be used.

The main sizes of the mounting hole of the discs:

  • 16 mm;
  • 20 mm;
  • 22 mm;
  • 30 m;
  • 32 mm;
  • 50 mm.

From the above indicators, the shaft size for the circular saw is selected.

The most common is a hole diameter of 32 mm. It is this landing seat that has disks with different sizes of the outer diameter. Alternatively, you can make a thinner shaft, so that it is possible to perform “jewelry” work. Then an adapter will be used to use large disks. To complicate the design of a home circular saw in this way is only in those cases when a professional will use it.

Saw blades are installed between two flanges and pressed with a nut, which is screwed onto a thread made on the edge of the working surface of the shaft.

Important! The thread should be left. During the inevitable jerk when starting the circular saw, the nut in this position will tighten, and not vice versa.

Bearing seats are determined according to the size of the latter. The largest diameter has the middle part of the shaft. If the indicator is significant, during rotation an additional load will be created on the belt. Reaming will help get rid of the problem, which will facilitate the heavy part of the shaft.

What discs should be used for circular saw

Productivity and quality of work to a large extent depend on a correctly selected disk for a circular saw made from a grinder, a hand saw or assembled from separate mechanisms. It should be remembered that discs for wood and metal differ. Even if thin, soft aluminum is to be sawed, the disc must be installed accordingly. Circles for cutting metal have smaller teeth. There are universal disc options that are applicable for working with both wood and metal.

There are differences and discs designed for longitudinal and transverse sawing of wood. Longitudinal sawing is carried out with a cutting nozzle with rare large teeth. But the transverse cutting will be better if you use discs with small frequent teeth.

As for the material and method of manufacturing disks, they can be monolithic and carbide. Monolithic are made from a single piece of high carbon steel. Such nozzles are inexpensive, but at the same time they have a significant drawback: they quickly become dull and need sharpening and wiring.

circular disks
Wood and metal discs are distinguished

Carbide wheels are made of tool steel soldered from cobalt and tungsten. They are more wear-resistant, but the price of such products is much higher.

The outer diameter of the disks for homemade circular saw is limited by the size of the protective casing. Standard disc thickness is 3.2 mm. There are thinner and thicker saw blades. Thin ones are used when working with wood of valuable species of trees to make a clean cut. Thicker wheels are recommended for rougher work.

Parallel stop for circular saw yourself

Parallel emphasis is a mandatory fixture on a circular saw table; without it, it is almost impossible to make an even cut. You can make it yourself as follows:

  1. Of the three strips of laminated particleboard, a U-shaped profile should be made, inserts should be placed inside and fixed, which will give rigidity. The result is a square section.
  2. A guide channel is made of two parallel rails, which is bolted to the end of the table in a position perpendicular to the saw blade.
  3. Then, an inverted T-shaped structure is made from MDF, which is screwed to the stop and inserted into the channel.
Parallel emphasis for circular saw
The parallel emphasis for a circular can be made independently

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

It is convenient to use original slots to fix the stop of a self-made circular saw made by hand. As a locking mechanism, threaded bolts, nuts and wooden washers are suitable, you will need a hole in the lower plane of the stop. Tightening the bolt contributes to a reliable clamping of the stop against the countertop. This design allows you to quickly and easily set the required cut sizes.

Circular saw table yourself

In this section, we propose a model of a universal table on which you can place a circular saw with any technical indicators and sizes. For the manufacture of the construction, the following materials will be needed:

  • a plywood sheet, preferably with a laminated topcoat, at least 10 mm thick and 800×800 mm in size;
  • 4 sheets of chipboard 16 mm thick (400×784 mm);
  • bars 50×50 mm;
  • bolts and screws.
prepared drawings
Circular saw with your own hands, will require prepared drawings

The manufacture of a table for a circular saw can be performed in the following sequence:

  1. From the sheets of chipboard, the upper part of the future table is assembled, which is a box without a bottom. The sides are fastened together with the help of bars, the length of which is much greater than the height of the sheets.
  2. The fabricated structure is turned over, the bars-legs of the future table in the lower part are fastened with additional jumpers.
  3. A tabletop is cut out of plywood, in which a longitudinal hole is made with a jigsaw – a saw blade will be inserted into it.

On the Internet it is easy to find a drawing of a similar design, which will greatly simplify the manufacture. You can upgrade the above-proposed version of the table for the circular saw with your own hands, replacing the bars with a metal corner or by doing the so-called box of boards. At the bottom of the structure, it’s nice to make a shelf.

Making trimming from circular saw

Laying a wooden floor, replacing platbands, lining the facade with planken, clapboard, creating landscape design elements require a dimensional board. The process of preparing such a board is called facing. That is, the ends of the material are cut in order to obtain the desired size of the workpiece and give the saw aesthetics.

Making trimming from circular saw
Trimming makes the work done faster and more economical

To make a crosscut from a manual circular saw with your own hands, you will need improvised material and a used tool. Standard features that future trimming should have are:

  • maximum cut length – 350 mm;
  • optimal engine revolving power – 4500 rpm;
  • low weight.

The upper part of the power tool is mounted on the kingpin using a large bearing – 150 mm (it will not be difficult to purchase on the market.) From the outside, ears are attached to the bearing. They serve to fasten the tool to the surface of the bed with M6 screws.

The main adaptations for the do-it-yourself circular saw are automobile shock absorbers (they are convenient to use as a broach), a soft start button and additional protection that attaches to the power tool and the bed.

Trim upper
The upper part of the trim is mounted on the king pin using a bearing

Important! Before assembling the structure, the shock absorbers must be disassembled, drain the oil from them and make air holes.

The advantages of a homemade cross-cut saw include the following:

  1. The design is easy to disassemble, and the power tool can be used for its intended purpose.
  2. Low cost. Excluding the price of the instrument (used), the costs will be no more than 7,19$.

Among the significant disadvantages it is worth highlighting high noise. To eliminate this drawback is almost impossible. In addition, it is necessary to do a test cut (selection and fixation of traction) in order to ensure good quality of subsequent work.

circular saw safety

If we take into account how much circular saw costs (from 230$- the most modest model) and compare the price with the cost of self-production (this is 60-90% less), then the difference is significant. But no savings will be justified when work safety is not ensured.

In order to avoid traumatic situations, it is worth adhering to the following recommendations:

  • do not use wood with metal inclusions (nails, corners, bolts, etc.) as raw materials;
  • sawing boards more than 200 cm in size should be done by two people;
  • working on a circular saw, you can not make sudden movements;
  • before starting work, be sure to wear glasses and gloves;
  • wood waste should be removed from the surface of the circular saw because it can cause a short circuit.

It is strictly forbidden to work on a home-made circular saw machine:

  • if the guiding device is not made;
  • there is no casing;
  • no fuses holding fingers;
  • propping knife above the saw blade.

A solid tool makes it possible to enjoy the work. And the result pleases with a high level of quality. Making a tool with your own hands will allow you to get the desired parameters and the necessary operational characteristics. It is impossible to be limited to superficial knowledge in any type of activity, especially in the technical field. It is worth undertaking an independent assembly of circular saws only after a thorough theoretical preparation and a full understanding of the practical part of the process.


Leave a Reply