Do-it-yourself reliable circular saw from a grinder. How to make a circular grinder with your own hands? How to make a circular grinder yourself

A circular saw, or more simply a “circular saw,” can be useful to any man both during major home repairs and just on the farm. And if you suddenly need it, you don’t have to run to the store to get it. You can take a grinder and, after spending a little free time, turn it into a circular saw with your own hands.

How to make a circular grinder with your own hands? This does not require special drawings or professional skills. You will need a little patience and the presence of some tools and improvised means in the house:

• cutting wheel for wood (150-180 mm);
• electric drill;
• reinforcing bars;
• metal clamps;
• bolts, nuts, washers.

Making a sliding stop

First you need to assemble a persistent-sliding structure for the future circular. To make this part, you will need two oblong metal corners - they will be located on both sides of the cutting wheel. It is advisable to sharpen the lower edges of the corners so that they do not scratch the workpiece when cutting.

Next, the corners are connected to each other at the edges with bolts and nuts, and a gap is left between them using washers. There should be a gap of 3-4 mm between the corners and the disk on each side so that the disk does not touch the edges of the stop during operation.

Then a clamp is put on the tool body with the tie down. The sliding stop must be firmly fixed to the screed. You can use galvanized tape.

Preparing the gearbox and making the axial handle

It is quite difficult to make a quality cut using a standard angle grinder handle. Therefore, it is recommended to make a handle with your own hands and then attach it to the grinder.

But first you need to prepare the instrument for such a modification. It is recommended to disassemble the tool gearbox and find areas suitable for drilling. Then drill several mounting holes with threads for a small bolt in the gearbox housing.

The handle itself is best made of metal (reinforcement, pipe or cross brace). At those ends of the handle with which it is attached to the gearbox, mounting holes are drilled. The handle is then attached to the tool using fasteners.

Making an adjusting rod

Before you start using a homemade circular saw, you should equip it with a cut depth regulator. The so-called adjusting rod.

A piece of reinforcing rod with a diameter of 5 mm is used as an adjusting rod. One of the ends of the rod is bent and flattened, then fixed with the front bolts of the corner stop.

A thread is cut at the other end of the rod. This is necessary for the rod to fit into the hole in the axial handle. Then a nut is screwed onto the thread, and the tail of the rod is threaded into the hole in the handle. After this, another nut is screwed on.

By loosening and tightening these nuts the depth of cut will be adjusted.

Thus, the hand-made circular saw is ready for use (video).

However, for greater convenience, you can turn it into a table saw. This will require a little more patience and available tools.

Converting a manual circular saw into a tabletop one

The first step in converting a circular saw from a hand tool into a table tool is to choose the table itself. It must be strong and stable. This is important not only for convenient work, but also for safety reasons. For example, an old kitchen table made of wood and metal might work.

Next you will need a reinforcing rod or metal pipe with a diameter of 15-22 mm. This pipe is bent (or cut and welded) in the shape of the letter “P”. Then the lower ends of this structure are bent, flattened and attached to the table in any convenient way - the main thing is that it stays strong and stable.

The two pieces of hollow metal pipe are then welded together to form a T-arm. Its transverse part must first be cut and bent so that it can be put on the crossbar of the frame, and then fastened with clamps. A ready-made manual circular is attached to the end of the lever itself, also with clamps.

So, the DIY desktop circular table is ready for use. If you replace the disk, it can be used for cutting metal. Unfortunately, it cannot handle thick lumber, and it is not very convenient to use for longitudinal sawing. For these purposes, you can try turning the angle grinder into a circular saw.

Circular saw

In this case, the grinder is mounted not above the tabletop, but under it. There is no need to convert it into a manual circular saw - just replace the disk and securely fasten it under the tabletop. To do this, you can use clamps, screws or specially made fasteners.

As with a tabletop circular table, the table must be strong and stable. It is desirable that it not just stand on the floor, but be screwed to it. The tabletop should be thick and preferably covered with thin sheets of metal - for better sliding of the supplied workpieces. You can also use chipboard.

The width of the gap in the tabletop should be, like that of the hand saw stop, 3-4 mm from the blade in both directions.

For more convenient work, you can equip the table with guides made of timber, screwing them onto self-tapping screws.

Important!

In conclusion, it should be recalled that the original purpose of an angle grinder is grinding and cutting hard materials. Therefore, when converting an angle grinder into a circular saw, you need to pay special attention to the following points:

• When using a grinder as a tabletop tool, remember that the lower edge of the disk should rotate towards the master, and the upper edge - away from him. It is also advisable to equip your machine with a protective plexiglass screen.
• Feeding of workpieces into the circular saw is done not by hand, but by other workpieces.
• The rotation speed of the grinder is significantly higher than the speed of the circular saw. When installing a cutting wheel for wood (150-180 mm) on an angle grinder, it is necessary to reduce the tool speed to 4000-5000 rpm.

Otherwise, the discs will become dull almost instantly. If the angle grinder you are using does not have a regulator, you can connect a special reduction gear to it.

A stationary circular saw is a machine that should be in the workshop of every craftsman who works with wood. With its help, you can quickly and effortlessly saw a board, cut a workpiece of the required size, or cut firewood.

A home craftsman simply must acquire such a machine. It is not necessary to buy it; a homemade circular saw is guaranteed to cope with the volume of work in a home workshop, and will cost a significantly less amount.

Circular saw device

Being a truly useful tool, the circular saw has a fairly simple design. Its main components:

• bed – frame on which the main units are mounted;
• tabletop with a slot for a disk;
• engine with rotation transmission system;
• cutting tool, disc with teeth.

Optionally, the device can be supplemented with a pusher, which ensures progressive movement of the workpiece towards the disk, and various lifting mechanisms that regulate the cutting depth.

The principle of operation of a circular saw (circular saw) is that the rotation of the electric motor shaft is transmitted to the cutting tool, a disk with sharply sharpened teeth. The center of the disk is located below the level of the tabletop, only a segment of it is removed from it. The workpiece is brought to the rotating disk, the teeth bite into the wood, creating an even cut.

A simple circular saw from a grinder or circular saw

An angle grinder (grinder) is one of the most popular home craftsman tools; it can be used to easily cut metal and clean welds. In addition, using a wood disc instead of a standard abrasive disc, the grinder can be turned into a hand-held circular saw (it is also called a parquet saw), and by making a frame with a table, it can be turned into a stationary circular saw.

Required accessories

To work you will need:

• multilayer plywood with a thickness of 10 mm or more;
• switch and wire;
• countersunk head bolts;
• screws;
• wooden block 40x40 mm.

You also need to prepare a drill or screwdriver, hammer, screwdriver, pliers, ruler and pencil. Using these tools you will have to make a circular saw with your own hands.

Of course, you must not forget the grinder itself or the hand-held circular saw. At the first stage, it will help to cut the material, and then it will take its place as the working body of the circular saw.

Sequencing

The first step is to make the body of the circular. Thick plywood is perfect for this; you can use any pressed wood boards. You will need to cut four rectangular sheets, size 40 x 80 cm. They are used to assemble a box with a square 80 x 80 cm at the base. For ease of assembly and reliability of the structure, four bars are installed in the corners.

The resulting box is closed on top with a table top. It can be made from the same plywood, but it is better to use some sheet material with a laminated coating. This guarantees the durability of the machine and ensures ease of use of the homemade circular saw.

A cut is made in the tabletop to allow the disk to come out, and holes are drilled on the sides for attaching the tool.

The grinder must be securely fixed under the tabletop. The design of the latch can be very diverse, it all depends on the configuration of the machine itself. The main requirement for fastening is that it must securely hold the angle grinder without allowing it to move.

The simplest fastening may look like this: two metal squares, a grinder is fixed between them with a steel clamp.

Two holes are drilled in the upper shelves of the angles holding the angle grinder. The structure is secured from below to the tabletop using countersunk bolts. All that remains is to block the power button and connect the angle grinder via an external switch.

In the same way, you can make your own circular saw from a circular saw. In this case, the work is noticeably simplified due to the fact that there is no need to invent a fastening. It is enough to make a cutout for the disk, drill holes along the holes of the plate with a hand-held circular saw.

Miniature machine made from a washing machine engine

The circular is distinguished by its extreme simplicity and availability of materials for its manufacture. Perhaps its only expensive part is the electric motor. Stationary machines are equipped with a powerful asynchronous motor, which ensures cutting of thick wood of any species, but in a home workshop you can limit yourself to less power.

Note! To cut boards of medium thickness, it is enough to make your own circular table driven by a washing machine motor.

This design has a number of advantages. An engine from an old washing machine is inexpensive; moreover, a similar unit can probably be found in a home craftsman’s household. Connecting this motor is not particularly difficult; there is no need to look for circuit diagrams or do soldering. With all this, the power of such a unit is quite sufficient for most types of work.

The machine diagram can be simplified as much as possible by eliminating the belt drive. In this embodiment, the cutting tool will be mounted directly on the motor shaft. The base of the desktop mini-machine will be a frame assembled from a block with a cross-section of 40 x 40 mm. If desired, it can be welded from a corner or profile pipe.

Part of the body of an old TV, coated chipboard, is ideal as a stand (tabletop) for a circular table. As practice shows, this part is quite durable, and thanks to the varnish coating, it does not prevent the workpiece from sliding.

Using a jigsaw, two parallel cuts are made in the tabletop perpendicular to the cutout for the disk. A movable square will slide along them, playing the role of a side stop. It will help you make an even cut, if necessary, at a given angle.

Stationary machine

Those who plan to get serious about woodworking should think about making a full-fledged stationary circular saw. This should be a separate unit installed on a workbench, equipped with a powerful motor, with the ability to quickly replace the disk. Making such a circular with your own hands will take time, but it will definitely pay for itself.

Despite the apparent simplicity of this device, before starting work it is worth creating a drawing of the machine. This will allow you to clearly see the future unit and choose its optimal configuration.

bed

The basis of any machine is the bed, the frame on which all the main parts are mounted. The frame of the circular saw must be stable and reliable, which is why it is made of metal. It is preferable to use a profile pipe or a thick-walled angle. Welding is used to connect parts. If a collapsible structure is planned, a bolted connection is suitable.

Buying a suitable material will not be difficult; in any specialized metal store you can pick up both pipes and an angle. Those who want to save money can be advised to contact scrap metal buyers. You can buy the same thing from them, only cheaper.

Tabletop

The best material for making the tabletop of a professional circular table is metal. Steel and aluminum-based alloys are excellent. For a budget option, you can limit yourself to thick multi-layer plywood covered with sheet iron. In any case, the surface of the tabletop must be smooth, resistant to friction and not bend under a weight of up to 50 kg.

A groove is made in the tabletop for the disk. It can be done in two ways. You can make a cut in a single sheet, or you can assemble a tabletop from two halves. The second method is preferable for a metal tabletop, which is difficult to cut into at home.

If desired, you can make a sawing machine for work outside the workshop; for this it is enough to provide the possibility of installing a low-power gasoline engine; it can be removable.

Rotation transmission

The optimal drive for a circular saw is a V-belt drive. Two pulleys are used, one on the engine and one on the drive shaft. It's convenient and safe. There is no direct connection between the motor rotor and the disk; if the tool jams, the belt will begin to slip, signaling the need to turn off the power. In addition, using pulleys with several grooves of different diameters, you can adjust the speed of the saw, choosing the optimal mode for different types of wood.

Rotation from the motor rotor is transmitted to the shaft. This is one of the most important parts of the circular. It is unlikely that you will be able to make a shaft yourself; it is better to buy a ready-made one or order it from a turner.

The shaft is mounted on bearings. They must be of a closed type: a circular saw is a sawing place and open ones will not last long.

Machine with pendulum engine suspension

Those who can boast of the ability to work with metal can be advised to make a circular machine with a pendulum engine suspension. The main feature of the device is that the motor, shaft and cutting disc are installed in one common frame. On one side it is hinged to the frame, the second is held in place by a screw with the ability to adjust the height. By changing the length of the screw, you can adjust the height of the disk exiting the tabletop.

This system allows you to adjust the cutting height, as well as use discs of different diameters. If, instead of an adjusting screw, you use a probe placed on the tabletop, you can get a simple copying machine. The feeler gauge will allow you to adjust the cutting depth according to a certain pattern. This fairly simple modification will turn a simple circular saw into a real woodworking machine. With this device you can not only cut the board into the necessary pieces, but also make precise cuts and make various selections.

A circular saw is an indispensable tool, which is very important not only when sawing firewood, but also when carrying out repairs in a house or apartment, as well as making furniture, etc. The circular itself is quite an expensive pleasure, but you shouldn’t rush to spend money on purchasing it. Such a tool can be made from a grinder. How to do it? It is this issue that this material is devoted to.

What will you need to create a circular saw from a grinder with your own hands? To do this, you need to make sure that the following structural elements are present:

• Bulgarian. It is advisable to use a powerful professional tool. Low-power grinders can only saw thin wood materials.
• Drill.
• Chipboards.
• Screws and glue.
• Plastic clamps.

First, you need to purchase a special circular saw disc suitable for an angle grinder. This disk must have teeth, the number of which depends on the size of the disk, as well as on the purpose of using the tool. First you need to worry about the base for the future circular file.

A homemade wooden table, a frame frame, or an old table will do as a base. The main thing for the foundation is stability, since vibrations will occur during operation.

It is important to know! The base can be assembled from scrap timber and plywood, which will be much more efficient and reliable.

When the base is ready, you need to take care of creating a stop for the angle grinder. It can also be made from bars and boards. The thickness of the stop should be selected so that the angle grinder casing has a tight fit to the side of the box without gaps. The length of the box should be sufficient to secure the angle grinder. You can also allocate space for a hose, which will be used to remove sawdust. The width of the stop will be equal to the distance from the bottom edge of the protective casing to the edge of the angle grinder body.

The stop is attached using self-tapping screws. The edges of the stop should not extend beyond the edge of the future work surface. At the third stage, you should secure the working surface to the base. Such a surface must be flat and smooth.

Installation of the grinder on the base is carried out with the tool turned off. Plastic clamps can be used as fasteners. The tool guard should not protrude beyond the working surface. After installing the grinder, you should check the ease of turning the disc using your hand. If the disk rotates without jamming or touching the structure, then the circular saw is almost ready for use.

To start work, you should set the desired cutting depth, and then fix the body of the angle grinder. Once everything is ready to start, you can perform a short test run. If everything is fine, then you can start the device and check it in action.

It is important to know! When using an angle grinder, it is necessary to check the heating of the electric motor. If it overheats, jamming may occur, so this should not be allowed.

Do not also forget that grinder discs intended for cutting wood cannot be used for sawing other materials: plastic, metal and other options. If at least one tooth is missing on the disk, then the use of such a tool should also be avoided.

Tabletop circular option

A circular saw from an angle grinder is a great way to save a significant amount of money. At the same time, it is important to understand that a homemade tool is not as reliable as a factory one, so do not forget about following safety regulations.

Making your own circular saw requires a little time and precision. If there is no confidence in the reliability of such a design, it is better to redo it immediately rather than test it on yourself. By simple but deliberate steps, you can even make a tabletop circular. The advantage of a tabletop circular is its compactness. It can be installed anywhere and gets the job done. This may be necessary in the case of renovations in the apartment, so as not to go down to the garage each time to cut out products of various shapes and thicknesses. Options for tabletop circular saws made from an angle grinder are shown in the photo above.

The main condition for tabletop circulars is the reliability of fixation of the base. It is best to secure the entire structure to a table or other surfaces when carrying out work to ensure complete immobility.

Option for a full-fledged stationary circular saw from an angle grinder

Making a full-fledged circular saw from a grinder is a more labor-intensive process than making a tabletop version. When making this option, you need to pay attention to the tool control buttons: start and stop. To do this, you will need to disassemble the angle grinder in order to remove the wiring from it to the control buttons, but in this case you can get an almost full-fledged circular saw.

As an angle grinder, it is recommended to choose models with a disk rotation speed of up to 7000 rpm. Small grinders produce up to 12 thousand revolutions, which is a very large value. Wood discs are not designed to work at such speeds, so it is very important to take the selection of angle grinders very seriously. When purchasing a disk, you should pay attention not only to its size, but also to its quality. A version of a full-fledged circular is presented below.

The video below shows a homemade circular saw using a German angle grinder, the spindle speed of which does not exceed 6 thousand revolutions. This option is simply ideal for making a homemade circular saw.

In conclusion, it is important to note that a circular saw is another irreplaceable thing that can always be useful when performing any work with wood.

An angle grinder, also known as an angle grinder, is an indispensable tool in the arsenal of any owner, used for cutting, grinding and polishing metal and wood. You can significantly expand the functionality of this tool with the help of homemade devices, which we will talk about in this article.

The publication will discuss a homemade frame for an angle grinder, which makes it possible to turn an angle grinder into a full-fledged cutting machine from an angle grinder, as well as other simple designs that can be made at home.

1 We modernize the grinder with our own hands - we make a cutting machine

The key advantage of an angle grinder is its mobility - it is a compact tool with an extremely wide range of applications. However, it also has disadvantages, including difficulties in processing loose parts, when cutting which there is strong vibration (which can cause destruction of the abrasive disc at high speeds) and the difficulty of maintaining the required dimensions of workpieces when cutting several structures of identical length.

The above disadvantages do not appear when the angle grinder is equipped with a cutting machine, which significantly increases the convenience of cutting both wood and metal. You can make such a machine for an angle grinder yourself, you will need:

• profile square pipe 40*40 and 20*20 mm;
• rectangular profile 40*20;
• metal corner 32 mm;
• bearings with a diameter of 32 mm;
• M12 studs;

When assembled, a homemade machine for an angle grinder is a square frame made of a 40*40 mm profile, reinforced with crossbars. A rocker arm is attached to the frame - a mechanism that holds the angle grinder, which allows you to change the position of the tool in the vertical plane.

A homemade stand for an angle grinder is made according to the following algorithm:

The resulting homemade frame for an angle grinder is quite easy to use. You need to install the angle grinder into the seat, position yourself to the right of the tool, place the workpiece on the supporting frame and lower the adjustment lever with your right hand. The cut itself is made in the space between the transverse crosspieces of the frame.

1.1 Circular saw from an angle grinder

Making a circular saw from an angle grinder is even easier than making a cutting machine, since there is no need to perform a large amount of welding work. The following materials will be required:

• old table;
• metal corner;
• construction clamps or corner;
• screws, nuts.

Let us immediately note that a low-speed angle grinder (within 4-5 thousand rpm) or one with adjustable speed is needed here, since units with high speeds are not suitable for cutting wood - due to rotation, the workpiece will be torn away from the circular saw, which poses a danger to the machine operator. For cutting wood, it makes sense to use an angle grinder with a disk with a diameter of 150 or 180 mm.

1.2 Making a circular saw from an angle grinder - video

2 Wall chaser from an angle grinder

A wall chaser is a tool used to form grooves and furrows on the surface of concrete and wooden structures. A wall chaser is necessary when reinforcing foam block masonry, hidden laying of wiring and cables. You can make such a tool with your own hands from an angle grinder without spending about 5-10 thousand rubles on the purchase of a factory unit.

An angle grinder turns into a full-fledged wall chaser after being equipped with a special casing made of wood or metal, which acts as a limiter that holds the circular saw at the same depth along the entire cutting length.

It makes sense to make the casing from sheet metal 2-3 mm thick. Decide on the width of the structure - the distance between the two side walls of the casing; it depends on the size of the disks used. After the main part of the structure, it is necessary to attach a clamp to the casing for installing an angle grinder. The fastening must be as strong as possible (welded with a continuous seam), since the vibration that occurs during operation can damage the connection.

A seat for attaching the handle is welded to the side wall. As a socket, you can use a piece of pipe with a hole drilled for a stud or bolt. In the upper part of the casing it is necessary to provide a pipe for the vacuum cleaner; without it, dust can clog the structure from the inside.

Please note that the angle grinder can only create grooves when two diamond discs are installed. In this case, the first disk is attached to the rod in a standard way, and the second - through a special spacer nut (the spacer should come complete with the angle grinder, or it can also be purchased separately). The thickness of the nut in this case determines the width of the groove being formed.

Do-it-yourself wall chaser from an angle grinder - video

2.1 Types of discs for angle grinders

In conclusion, a few words about the types of discs for grinders. All discs are classified into four main groups - cutting, grinding, sharpening, roughing.

Cutting discs are available in diameters of 115, 125, 150, 180 and 230 mm, their thickness can be 1-3.3 mm, and are blue. The marking indicates the type of abrasive material: A - corundum, C - silicon carbide, AS - electrocorundum. The markings also indicate numbers indicating the grain size - the larger it is, the higher the cutting speed and the lower the accuracy. The mounting hole in the cutting discs is reinforced with steel plates, which ensures its strength, since the ring experiences maximum loads during rotation.

For cutting stone materials, special diamond discs are used, which can be solid or segmented. The last option is designed for heavy work - they can cut asphalt, granite, and marble. Cutting tiles with a grinder can be done using solid discs; they are designed for working with soft materials and differ from their segmented counterparts in having worse natural cooling.

Grinding discs are extremely variable; they are available with different abrasive surfaces - from emery to sponge and felt (polishing discs). The grinding itself is performed using special pastes that moisturize the surface being treated and thereby reduce the amount of dust released.

Sanding discs with metallic bristles are used to remove old paintwork, scale, and cement mortar. There are also diamond grinding discs, which differ from cutting discs in the shape of their edges. Such discs are not used on metal surfaces; they can only be used on stone and concrete.

Many representatives of the stronger half of humanity simply need such a thing as a circular saw, but it is quite difficult to purchase it due to its high cost.

A circular saw is a cutting tool based on a metal disk with external teeth.

But experienced experts say that it is quite possible to make a circular machine on your own. To do this you need to have patience, an adaptation for a workbench and a mechanism such as a grinder. Of course, for this you need to have other materials, for example, steel corners (enough pieces), a rectangular pipe from a profile and an engine.

Read also:

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The main method of making a circular saw

If you have a grinder, then the process of making such a saw is much simpler. To do this, you need to make a stop (sliding) and a handle. First you need to understand what this emphasis is. It consists of two pieces of small corner made of metal, which are located on two sides of the main mechanism, that is, a special disk with teeth. It is installed instead of an abrasive wheel. The gap on either side should be about 4 mm.

The chamfers of the corners are rounded horizontally from below so that they cannot adhere to the part that will be processed. These metal corners are connected both front and rear by transverse fasteners, which can be nuts and bolts and a pack of washers.

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The process of making a circular saw from a grinder with your own hands

The axial handle is made from an iron tube or an ordinary twig, which looks like horns pointing forward and upward. Perhaps these will be transverse staples having a certain width, usually equal to the width of a man's palm. At the ends that will be attached to the gearbox, it is necessary to drill holes for bolting. At the same time, you must not spill them, otherwise the handle will become easily bendable. To make a handle for a circular saw in the form of a horn, you need to splash the far end on a horizontal surface and drill a hole for the corresponding axis (4-6 mm plus a margin of 2-4 mm).

If the handle is made in the form of a bracket, then a piece of twig is fixed into the holes of the gearbox, and the outer part is spilled and a hole is drilled in it. Next, an adjustment rod is made, for which a steel rod measuring 4-6 mm is taken. One end of it is bent into a loop, splashed a little, after which a hole is drilled for the stop bolt at the front.

On the equipment of the grinder, or rather its body, it is necessary to put on a clamp, the screw tie of which is located in the lower part. A tin strip is attached to this tie, which is folded in half. It is also possible to strengthen it with galvanization, which has a hole for the rear bolt for a sliding stop. The thickness of the strip must be at least 1.5 mm. Equal clearances can be achieved by repositioning the washers.

Two to four holes are made in the body of the gearbox, threaded for small bolts.

To do this, the gearbox is disassembled and the drilling location is determined. These holes will allow you to attach an axial handle. At the very end of the rod, a thread is cut that will fit into the hole on this handle. Thanks to this, the circular saw has the ability to regulate the level of the cut, that is, its depth. The fact is that one nut fastener is screwed into the threaded end in advance, and after the circular is assembled, a second one is screwed in. If the nuts are alternately tightened or loosened, precise adjustment of the cut can be achieved. Now you know how to make a circular grinder out of an angle grinder on your own.