< a href = "https://usamodelkina.ru/uploads/posts/2021-08/1629549339_screenshot_2021-08-04-14-46-44-941_com_google_android_youtube.jpg" rel = "prettyPhoto"> Hello everyone! In today's article, we will take a closer look at the manufacture of a useful hand tool, namely, we will consider the manufacture of a hand-held cordless circular saw. I think there is no need to tell the usefulness of a circular saw, many already know that this is an insanely useful and often nailed tool for any home and not only craftsman. This homemade product, like most homemade products in general, should not be considered as a professional tool, but it will be more than enough for household needs, especially since the total cost of this homemade product will be an order of magnitude lower than the cost of even the simplest cordless circular saws. The design itself will be extremely simple, and if you have a need for such a tool, then surely your skills will already be enough to assemble this homemade product. Well, well, I think you shouldn't delay with a long preface, let's go.
You can find links to some of the components at the end of the article.
For this cordless hand-held circular saw, we need the following, namely:
– The circular saw blade itself
– Mount for circular saw blades
– Round metal bar (shaft)
– Belt drive pinion and pinion
– Small piece of thick plywood
– Small plastic fox
– Electric motor
– Electric motor speed controller
– Throttle trigger
– Wooden block
– Plug for PVC sewer pipe
– A small piece of plastic water pipe
– Self-tapping screws
From the tools we also need the following:
– Hacksaw for metal
– Soldering iron with all the necessary soldering accessories
– Drill with a set of different drills
Making a cordless hand-held circular saw:
To begin with, we need to get a special mount for the cutting disc, with which it would be possible to fix the cutting disc on a shaft of a suitable diameter. In principle, without this mount, the continuation of the assembly will be impossible. Such a mount can be dismantled from some old and broken grinder or circular saw, if you didn’t find such a good, then it’s okay, since the Chinese have already come up with everything and in their Chinese online stores we can buy the mount we need.
< a href = "https://usamodelkina.ru/uploads/posts/2021-08/1629549341_screenshot_2021-08-04-17-07-42-550_com_google_android_youtube.jpg" rel = "prettyPhoto"> Having found the necessary mount that allows us to attach the cutting disc to the shaft, we need to make the shaft itself and the housing in which it will be installed and rotate around its axis. To do this, we need to select a pair of bearings of suitable diameter. Inside which you could press the shaft of your choice. Having pressed the bearings onto the shaft, it is necessary to put a plastic pipe of a suitable diameter on the bearings. That is, the outer diameter of the bearings must match the inner diameter of the pipe. And to make the pipe more densely set, you can warm it up, and it will shrink like heat shrinkage (albeit several times less shrinkage), but the effect itself will give.
The next step is to take the previously prepared blanks and connect them to each other, or rather, take the mounting of the cutting disc and fix it on the rotating shaft. Further, on the reverse side of the mounting of the cutting blade, it is necessary to fix the gear (pulley) of the belt drive. We can also immediately install the cutting disc itself and rotate the shaft to check the presence of beats, it is important that the cutting disc does not “go eight”.
< a href = "https://usamodelkina.ru/uploads/posts/2021-08/1629549343_screenshot_2021-08-04-17-19-44-012_com_google_android_youtube.jpg" rel = "prettyPhoto"> < img class = "aligncenter" alt = "Compact cordless circular saw" src = "https://usamodelkina.ru/uploads/posts/2021-08/1629549345_screenshot_2021-08-04-17-21-09-701_com_google_android_youtube.jpg"/> Next, we need to fix the resulting structure on some kind of foundation. The author of the homemade product cut this base out of ordinary plywood, if you have a piece of film faced plywood, then it is better to use it, since film faced plywood is waterproof, durable and will slide better than ordinary plywood. The base should be such a width that only one part with the cutting disc protrudes, in order to make the cut deeper, the author of the homemade product had to cut a special groove for the driven pulley so that neither he nor his belt would rub against the base. < br> We fasten the base with the body of the rotating shaft, while on superglue. Further, the connection will be strengthened. You should also take a sheet of plastic and cut out a rectangle from it, which we glue to the plywood base, just like the author of the homemade product in the photo below did it.
< a href = "https://usamodelkina.ru/uploads/posts/2021-08/1629549349_screenshot_2021-08-04-17-54-27-189_com_google_android_youtube.jpg" rel = "prettyPhoto"> < img class = "aligncenter" alt = "Compact cordless circular saw" src = "https://usamodelkina.ru/uploads/posts/2021-08/1629549351_screenshot_2021-08-04-17-55-23-585_com_google_android_youtube.jpg"/> We turn to the manufacture of a motor mount for our electric motor, for this we take the same sheet of plastic, this time we need to saw off two square blanks from it, which will need to be glued together using superglue. Then the author decided to sand the edges and grind off the corners, thus making the workpiece semicircular.
< img class = "aligncenter" alt = "Compact cordless circular saw" src = "https://usamodelkina.ru/uploads/posts/2021-08/1629549353_screenshot_2021-08-04-17-57-01-041_com_google_android_youtube.jpg"/> After that, in the workpiece of the motor mount, in order for it to become a full-fledged motor mount, it is necessary to make a couple of mounting holes and one for the motor shaft. To do this, we take the electric motor of your choice (the author of the homemade product chose an “airplane” brushless electric motor) and attach it to the motor mount, mark with a marker the places for making all the necessary holes listed above. We take a drill with drills of the required diameter and carefully make holes in the places made.
We install the electric motor on the newly made motor mount. Then we install the drive pulley on the motor shaft and fix it there with a fixing nut (or, in your case, perhaps a screw). Next, we take the belt and put it on the driven and driving pulleys. Putting the belt on the pulleys, we need to fix the motor mount on the base by gluing it on superglue to its plastic part, but you need to glue it in such a way that the installed belt is in a taut position. It is important that the belt is stretched and at the same time not overtightened, that in the first and in the second case there will be nothing good.
< img class = "aligncenter" alt = "Compact cordless circular saw" src = "https://usamodelkina.ru/uploads/posts/2021-08/1629549359_screenshot_2021-08-04-18-06-53-168_com_google_android_youtube.jpg"/> < a href = "https://usamodelkina.ru/uploads/posts/2021-08/1629549360_screenshot_2021-08-04-18-08-57-356_com_google_android_youtube.jpg" rel = "prettyPhoto"> Having installed the engine with the motor frame in its place, the author immediately connected the engine to the speed regulator. And the speed controller itself was fixed on the same basis as the motor mount of the electric motor. It is necessary to connect the throttle trigger to the speed controller itself, the author decided to use a servo tester, which will also be fixed on the base, and the saw itself will start from the usual button, that is, it will be necessary to select the saw speed earlier before starting the sawing process itself.
< a href = "https://usamodelkina.ru/uploads/posts/2021-08/1629549363_screenshot_2021-08-04-18-13-31-303_com_google_android_youtube.jpg" rel = "prettyPhoto"> Further, the author decided to strengthen the connection of the shaft body to the base, for this he cut out from plywood and assembled an “L” shaped blank, which he first glued to the base and to the body, and then reinforced the connection with self-tapping screws.
< a href = "https://usamodelkina.ru/uploads/posts/2021-08/1629549366_screenshot_2021-08-04-18-18-43-091_com_google_android_youtube.jpg" rel = "prettyPhoto"> < img class = "aligncenter" alt = "Compact cordless circular saw" src = "https://usamodelkina.ru/uploads/posts/2021-08/1629549367_screenshot_2021-08-04-18-18-48-856_com_google_android_youtube.jpg"/> We turn to the manufacture of the handle. The author made the handle from an ordinary bar, and into which, behind the scenes, he integrated the button into the battery case, which he cut out of plywood. And also immediately painted the whole thing. Having made the handle, we screw it to the reinforcing part of the structure that we installed on the basis of a step earlier.
Then we install the battery into our case. The author's rechargeable battery is assembled from 18650 batteries, it is worth noting the fact that these batteries require a special charge and discharge controller, otherwise you will quickly ditch your batteries. Having installed the battery in its place, we connect everything, namely the power supply of the regulator through the button.
< a href = "https://usamodelkina.ru/uploads/posts/2021-08/1629549376_screenshot_2021-08-04-18-31-50-153_com_google_android_youtube.jpg" rel = "prettyPhoto"> In fact, the tool is ready, but in this form it is extremely dangerous to operate it, it is necessary to make a protective casing, the casing will be made of PVC sewer pipe plugs, here I think everything is quite simple and this process does not require any extra comments.
< a href = "https://usamodelkina.ru/uploads/posts/2021-08/1629549380_screenshot_2021-08-04-18-36-51-814_com_google_android_youtube.jpg" rel = "prettyPhoto"> < img class = "aligncenter" alt = "Compact cordless circular saw" src = "https://usamodelkina.ru/uploads/posts/2021-08/1629549381_screenshot_2021-08-04-18-36-58-258_com_google_android_youtube.jpg"/> All is ready! As a result, you have a useful tool that can help you out more than once when you need it.
< a href = "https://usamodelkina.ru/uploads/posts/2021-08/1629549384_screenshot_2021-08-04-18-37-22-834_com_google_android_youtube.jpg" rel = "prettyPhoto"> Here is a video of the author of the homemade product:
– Circular saw blade
– Circular saw blade mount
– Belt drive gears and the belt itself
– Class 775 collector motor
– 18650 batteries
– Motor speed controller
– Throttle trigger
Well, thank you all for attention good luck in future projects, DIYers!