How to Make a Circular Out of a Hand Circular Saw

If a person lives in a private house or has a summer garden, then the presence of a stationary circular saw in the arsenal of a home master is not only desirable, but sometimes necessary. Unfortunately, the cost of an industrially manufactured sample of such a saw does not correspond to the frequency of its home use, and for some Russians it is simply not affordable. At the same time, making a “circular” with your own hands is quite simple, using the drive of a sewing machine or an ordinary electric drill. However, the quality of the work and the nomenclature of the operations performed largely depend on the bed of the circular saw.

Bed construction

How to Make a Circular Out of a Hand Circular Saw

The simplest frame of a circular saw, the drive power of which does not exceed 0.8. 12 kilowatts, is quite affordable to make with your own hands from thick plywood and wooden blocks. For the drive, you can use the electric drill “BOSCH GSB 19-2” (power 0.85 kilowatts) or “DWT SBM-1050” (power 1.05 kilowatts), which is fastened to a plate under a special bracket. The length of the bed will depend on the length of the material being cut. For the table, you need to purchase bakelite plywood with a thickness of at least 50.0 millimeters. Of course, a wooden bed is not suitable for professional work, but in order to dissolve the boards, quickly cut the bars, such a home-made design is quite enough.

In the general case, the bed will consist of a base and a tabletop (desktop). Of course, with manual manual manufacturing of a circular saw, one must strive to simplify the design as much as possible. The design of the desktop will primarily be determined by the design of the attachment site of the cutting disc. In home-made circular devices, either a circular disk mounted directly in the electric drill chuck is used, or (more preferably) two support shafts driven into rotation from the electric motor through a belt drive.

Countertop Making

At the first stage of manufacturing a frame with a wooden table top, do-it-yourself plywood sheet is placed in accordance with the existing sketch or drawing. In order to reduce the number of cuts, marking is carried out from the edges of the sheet. A hacksaw with a small tooth or a jigsaw is used as a tool.

On the underside of the sawn off piece, a slot for the disk is marked. Propyl can be performed with a finger mill, fixing it with your own hands in the chuck of an electric drill. In order to maintain the straightness of the edges of the cut, the simplest home-made copier from two metal corners is attached to the countertop with clamps.Further work depends on the mounting mechanism of the circular saw blade. The simplest way is to manually install it on two bearing bearings, and drive through a belt drive from a separate electric motor or from an electric drill.

To give additional rigidity to the countertops along its edges, it is desirable to fix stiffeners, which can be made of bars or aluminum corners. The stiffening ribs are fixed to the table using self-tapping screws. To give greater strength to the entire structure, an additional layer of epoxy glue can be applied to the joint, which will fix the bar to the countertop along the entire plane of the joint.The distance from the edge of the countertop to the bar should be equal to 2.0. 4.0 centimeters.

After that, in accordance with the selected drive design, the supporting unit of the circular disk is attached. For reliability of fastening, fixing the bearing housings to the bed is best done using a screw, threaded connection. In this case, countersunk screw heads are located on the upper plane of the countertop and should not protrude above its plane. The upper working surface of the desktop should be coated with wear-resistant varnish and polished.

For greater safety when working with a home-made device, it is advisable to install a swinging protective cover over the cutting edge of the disc.

Base construction

For safe operation of a home-made circular saw, the table must be mounted on a sufficiently rigid and strong base. To make it in a manual way, the master’s fantasies are given complete freedom. The base can be made in the form of a wooden table, but it is better to weld from a corner (such as an aquarium frame) in accordance with the size of the countertop.

Some manufacturing nuances

The main parameter that determines the design of a home-made “circular” is the thickness of the sawn boards. For household work with their own hands, it is usually not necessary to cut wood thicker than 15.0. 20.0 millimeters. To change the depth of cut, you can use and / or make a special mechanism for lifting the disc, but this will greatly complicate the design of homemade.

When choosing a drive motor, the rotational speed of its shaft should be taken into account. Using a belt drive, you can make a change in the number of revolutions with your own hands. If you intend to use an electric drill as a drive, then preference should be given to models with a variable frequency of rotation of the chuck, then using such a circular saw made by yourself will be a pleasure.


Despite the primitiveness of the design described, it will significantly facilitate homework with your own hands, starting from carpentry operations with boards and ending with the transverse sawing of thick knots cut from garden trees.