Making a table for a hand-held circular saw with your own hands

Design requirements

Experienced craftsmen are ready to create a table for a circular table with their own hands without any techniques or drawings. However, certain conditions still need to be taken into account.

The essential requirements include:

• rigidity (stability) of the system;
• flat, smooth surface of the table;
• securely securing the saw;
• the presence of a guard from the cutting disc;
• free access to the start and pause buttons.

The availability of different functions depends on the working conditions and wishes of the specialist. These include the ability to carry out high-quality longitudinal and transverse cuts.

Standard products, of which there are hundreds in shopping centers, are made of stainless steel. This is an excellent material , but next we consider the production of a table for a saw from wood .

Conclusion

Due to the fact that the issue of choosing the right formatter is most acute for representatives of small businesses, let us summarize based on the needs of these customers.

the most acceptable option for starting production activities is the inexpensive Woodtec 3200 R. Its capabilities are sufficient for the leisurely production of cabinet furniture according to individual projects.

Altendorf F45 , due to its reasonable price and high cutting accuracy, in general terms outperforms even the most expensive representatives of format cutting machines.

Desktop device

The design of a table for a manual circular saw is so elementary that most specialists produce it without preparatory drawings and techniques. This is a dense workbench that is created from wood and plywood.

The most durable table bases are made from alloy. They are the heaviest and require the presence of welding skills. Therefore, stands are often made from leftover lumber. A circular saw is attached under the tabletop, and the drive protrudes above it through a specially made slot. The lumber is advanced along the table top and sawn with a disk. For convenience and correct operation, the table is equipped with additional devices: an angular and longitudinal stop.

The tabletop “absorbs” part of the working plane of the disk; the depth of cut will decrease by the thickness of the tabletop. For this reason, it is preferable to choose a circular saw with the largest disk diameter, and a table cover that is thin but rigid.

If you have not purchased an electric saw yet, choose modifications with high power (from 1200 W). They can handle cutting large-sized wood. Holes will be drilled to secure the base. The solid base may burst. For this reason, it is advisable to select a mechanism of a different type.

How to install the saw correctly

The next step is to properly position the saw on the top surface of the saw table. To do this, the contractor must perform the following actions:

1. Install the tool so that its working part fits into the pre-prepared groove.
2. Mark the locations for the M8 plowshare bolts with countersunk heads (they will be used to secure the saw blade).
3. Drill the plywood from the top to make equal holes with a diameter of about 8 mm.
4. Make a countersink to countersink the bolt heads.
5. Carefully install the metal saw blade and carefully tighten the bolts from the bottom using nuts and lock washers.

The work of making a machine requires great concentration and concentration. The slightest mistake can lead to having to start all over again.

After securing the structure to the table, you need to install a block to turn the circular saw motor on and off. A hole is cut in the housing, the switch is secured with bolts and universal glue. There should be two separate cables coming from the unit. One to the instrument, the other to the nearest electrical outlet.

When assembling such a unit yourself, it is worth taking into account the performance of the motor, as well as the maximum power of the electric motor. In this case, experts advise choosing a motor whose power does not exceed 1000–1200 W, otherwise operation may be unsafe. And a more powerful saw means a heavier and more stable table.

Install the tool so that its working part fits into the pre-prepared groove

Mark the locations for the M8 countersunk plowshare bolts

Install the metal saw blade and carefully tighten the bolts from below

Install a block to turn the circular saw motor on and off

Selection of material

To make a circular table with your own hands, you need to remember carpentry skills, have a lot of patience and a small number of materials and devices.

Materials:

• plywood 15-20 millimeters;
• timber 50×50;
• board;
• switch;
• outdoor socket;
• a piece of cable;
• PVA glue;
• varnish;
• self-tapping screws

Devices:

• jigsaw;
• screwdriver;
• drill;
• ruler.

The volume of the countertop will depend on the workshop area. At the same time, it will be uncomfortable to saw large pieces on a small table. If the part fits completely on the working plane, the cut is made smoother and more accurately. The height of the legs is chosen depending on the height of the master.

Griggio UNICA SAFE – from 850,000 rubles

A line of 5 dimensional options for reliable and safe format-cutting machines, with programmatic control of the saw unit.

For ease of operation, the carriage is locked in any position. To remove backlash as the rollers wear out, the movable frame is equipped with reversible screws - this detail provides a stated 10-year warranty on the carriage mechanism. There are systems for smooth speed control and instant stop of the saw blade, and a digital indicator on the ruler. The readiness of the machine for operation is indicated by LEDs on the desktop. Fast and precise adjustment of the position of the scoring and main equipment is ensured by separate drives.

The need to replace critical elements of the safety system after each operation makes it very expensive to operate a far from cheap machine.
The base disk Ø 400 mm, when the saw unit is lowered into the table as much as possible, still remains 25 mm above the surface of the machine. A Ø 300 mm disc is ideally hidden. Technical characteristics of the Griggio UNICA SAFE machine

Video about the Griggio UNICA SAFE machine:

Table production process

• You need to cut a tabletop of the required size from a sheet of plywood. Markings are applied to the lower area using a metal ruler and pencil. Cut the plywood with a jigsaw, milling the edges if necessary. If the plywood is not laminated, we clean the surface of the table with sandpaper.
• They shift it and make markings from the bottom for attaching a manual circular saw. To do this, remove the disk from the device and place it with the sole in the required place. We make marks on the table top and at the base for fasteners and a hole for the saw blade. Drill holes for the bolts. They will be twisted from above under the tabletop and held in place with nuts at the bottom. Therefore, the holes are countersinked from the edge of the working plane, and the bolt heads are leveled so that they do not protrude.
• If it is planned to cut the material at different angles, the slot for the saw-tooth circle is made in the shape of an inverted trapezoid. For straight sawing, an ordinary groove is made. Before marking the slot and holes for fasteners, you need to apply a saw, adjust the marks and only then cut.
• Draw with a pencil the areas where the stiffening ribs are located. They are made from boards and installed below 8-9 cm from the edge of the tabletop itself. The table legs must be fixed to the ribs. The ribs are secured with self-tapping screws at intervals of 15–25 cm, and in addition they are glued with PVA. Self-tapping screws are screwed on top, under the tabletop, the heads are completely recessed. The ribs are fastened together with self-tapping screws.
• The legs are made of timber or boards, their length will be from 100 to 113 cm. The legs diverging downwards will give significant stability. They are fixed with large bolts twisted on the outside and reinforced with nuts on the inside. Timber ties will strengthen the frame.
• In order to adjust the height of the table, nuts are attached at the bottom into which M14 bolts are screwed. Now you can secure the saw from below by passing the drive into the prepared slot.
• We attach an electrical outlet to the table, run an electrical cable from it and set the switch. Power to the outlet will be transferred from the switch. We stretch the cable from it to the nearest source in the workshop. With the support of the construction screed, we fix the ON-OFF key on the body of the circular saw in a recessed state.
• Let's start producing auxiliary stops. For the stop you will need a number 30 square cut aluminum pipe and 2 screws with wing nuts. We saw off a piece of pipe along the length of the tabletop, making holes for screws 3 cm from the edge. 2 clamps are cut out from pieces of plywood. The system is ready.
• To process across the table, we use a plywood sled. We align them with the edges of the table, press them down and move them along the toothed circle. We cut a hole in the passage area of ​​the circle. Small components can be placed directly inside the slide and sawed. Dust will be removed from under the table, but a significant part of it will still fly upward, so it is good to supplement the device with an upper dust extractor.

Working with a circular saw is very dangerous , for this reason it is necessary to take care of protecting your fingers. Cut a pusher from a piece of wood or furniture board.

Additions to the completed design

Some craftsmen, when assembling a table for a hand-held circular saw according to unique drawings, completely remove the factory safety cover and replace the factory platform with a homemade one. If cutting at an angle is not planned, you can remove all devices for adjusting the tilt of the disk. The electric saw is fixed directly to the new base, which makes it possible to gain a couple of millimeters of cutting depth.

Without an internal casing , it is easier to remove the blade; the electric saw will not become clogged with shavings when working with wet boards. Dismantling will require extra time, but the service life of the motor is preserved and overload is prevented.

Mounting a circular saw

The matter remains small. The circular electric saw is located inside the prepared hole. The sole is secured with bolts , and the gear drive must fit freely into the socket.

The table for the circular saw is almost ready. Now it needs to be treated with a moisture-protecting material, then coated with varnish in several layers (to minimize slipping).

The resulting system can be supplemented with anything at the user’s discretion (safety cover, device for adjusting the tilt of the disk, carriage, etc.).

Manufacturing stages

Before assembling the machine for cutting boards, logs and blanks, you should prepare all the necessary materials and tools. To work you will need:

• moisture-resistant plywood;
• sheet material suitable for making the body;
• elements for the body and legs (bars 40 by 40 mm).

Fastening will be done with self-tapping screws using a screwdriver. All necessary parts are cut with a jigsaw. A saw with a disk of suitable diameter is also prepared.

Algorithm for creating a table:

1. Sawing all parts into pieces with the required dimensions.
2. Marking the mounting areas for the saw and legs on the table top.
3. Making a case, which is usually a rectangular box without a lid or bottom.
4. Installation of countertops.
5. Cutting a hole that should be 5–10 mm longer and 4–6 mm wider than the disc.

If you cut the material at a certain angle, the resulting slot should resemble a trapezoid (inverted) in shape. For smooth sawing, a regular hole is made. Before cutting out the groove, you should apply a saw and adjust the marks.

Sawing all parts into pieces with the required dimensions

Marking the mounting areas for the saw and legs on the tabletop

Case manufacturing

Installing the countertop and cutting the hole

Preparing to install the saw

A few words about electronics

A circular saw is electrical special equipment that operates from a 220 V power source. If the user has sufficient knowledge and skill in the field of electronics, he is able to bypass the start and pause keys of the saw, and then move them to a convenient place (usually the outside 1st of the stiffeners).

If the model seems complicated, you need to tighten the start button with a wire, and turn on the special equipment using a power cord. However, this method is bad because it eliminates the possibility of quickly turning off the device in the event of an emergency.

Altendorf F45 – from 450,000 rubles

The basic version of the line of format-cutting machines designed to work on an industrial scale with chipboard, solid wood, plasterboard, plastic, and aluminum. Electronic adjustment of the disc position. Indication of everything: from current values ​​to error codes. Convenient and reliable systems for fixing disks on shafts. Manual installation of stops using a fine adjustment mechanism. Convenient location of the control unit. Smooth adjustment of saw blade rotation speed.

Taking into account the list of all available basic solutions, the relatively high cost of new and used equipment becomes justified. Another plus is that to adapt any model of the updated F45 line to the technical conditions of a particular production, a proprietary list of additional equipment of 15 items is offered.

Keep in mind: if the scoring disc rotates in the same direction as the main one, this is not a breakdown, but a feature of the Vario motor control unit.
This is how it reacts to errors in connecting to a three-phase network. In order to start the machine correctly, you just need to swap the phases. The main drive here is controlled by a frequency converter, so phase reversal does not affect its operation in any way. Technical characteristics of Altendorf F45

Video about the Altendorf F45 panel saw:

Safety requirements

1. One of the most common causes of injuries when using a circular saw is considered to be a cluttered workplace. In addition, it is important to monitor the stability and strength of absolutely all components of the system, and if there is imbalance, take measures to eliminate difficulties.
2. Before connecting the saw, you must make sure that it is well secured. If necessary, tighten the screws/bolts.
3. It is strictly forbidden to hold the material close to the cutting site! This is dangerous as knots and chips bounce into the eyes or onto open parts of the body. Be sure to wear glasses before work and clothes with sleeves.

Making your own saw table is not as difficult a task as it might seem. If you have good material at hand, its characteristics are chosen correctly, and the power of the device ranges from 500 to 1000 W, the above instructions will be the basis of the work.

You should not lose sight of the fact that at any stage of table production you should control the accuracy of your own operations. Otherwise, if deviations in size or deformation of the legs appear when the ribs are tightened, it will be very difficult to restore stability. Nevertheless, making a table for a circular table with your own hands is an absolutely realistic task that will take several hours.

Holz-her 1270 – from 220,000 rubles

Format cutting machine with a vertical table – for transport cutting of dimensional slab materials.

Takes up minimal space. There is a semi-automatic feed of the saw unit with return to the starting position. The design allows you to quickly adjust the cut size and change the cutting axis in two movements.

Does not allow cutting a sheet of material diagonally.
Despite the pneumatic clamping of the workpiece to the table, it is inconvenient to cut and remove large parts alone. Please note: the design of the saw unit does not provide for a scoring disc. Therefore, only equipment recommended by the manufacturer is used. High-quality cutting using analogues of branded blades is possible only if it fully complies with the specifications of the “original” cutting part of the equipment. Technical characteristics of Holzher 1270

Video about the Holzher 1270 panel saw:

Additional Important Information

Carpentry work requires special attention. If you want to make a high-quality and highly reliable table for a circular saw with your own hands, then be well prepared for the work.

Do the following:

1. Purchase all the necessary materials and equipment without exception.
2. After installing the frame, be sure to install it on a flat plane and check that the cover of the structure does not overhang in any direction.
3. It is better to install the table for the circular saw in the area where it will be located in the future in order to eliminate possible problems associated with uneven floors.
4. If, due to the rough floor, the table vibrates during operation, then it is necessary to adjust the length of the legs using compacted material or rubber.
5. The product tabletop can be either single or folding. In order to form a folding table for a saw, it will be necessary to spend a little more time and the material itself and pay attention to increasing the strength of the frame, which is in a disassembled state.
6. The dimensions of the material used to create the table are determined experimentally. Ideally, the level of the design should correspond to the height of the master.
7. The hole that will be made in the tabletop must correspond to the dimensions of the specific saw available.
8. To extend the service life of all materials used, assembled into a common structure, it is necessary to subject them to treatment with special chemicals that can increase the working properties of wood or metal (for example, protect their surface from rust, rotting, mold, etc.).
9. It is better to process wood or iron outdoors, rather than indoors, to avoid poisoning from intense fumes.

Using this article as inspiration, you can make a durable table saw stand for your circular saw.

Woodtec 3200 R – from 155,000 rubles

An upgraded version of the entry-level machine.
For cutting standard versions of wood-based panels, up to 5-10 sheets per day. The roller carriage ensures maximum precision and smooth running. Adjusting bolts are provided to remove the lateral play of the movable table. The welded frame determines the strength of the machine. The cast base of the saw unit prevents the occurrence of tool runouts throughout the entire life of the machine. The aspiration system housing is held by the riving knife, and the knife itself is not rigid enough to keep the housing from vibration. If the laminated chipboard is fed unevenly, this nuance can provoke a sharp increase in the amplitude of vibrations of the casing, its beating on the disk and trembling of the sawn board. This is why laminate chips even on high-quality material.

The first experience of working on this particular machine should be obtained only after professional adjustment.
Without a guaranteed correct setting, it cannot be turned on for testing - the same riving knife, due to its low rigidity, does not allow one to determine its weakened fastening even by touch. Which can cause damage to the blade, drive and saw unit. Technical characteristics of the Woodtec 3200 R format saw

Video about the Woodtec 3200 R panel saw:

Therefore, we decided to make a format-cutting machine with our own hands.

For assembly I needed:

• A circular saw. I used Metabo at 1.25 kW - a quite inexpensive option around 4.5-5.5 thousand rubles. The disc was used for cutting laminate - it implies a cleaner cut
• 3 m bars (40*60 and 50*50 mm, I used 14 pieces in total) - we use them to make a supporting frame
• Polished shafts - 20 mm 2 m for 2400 rub. (2 pcs) and 10 mm 2 m for 900 RUR (2 pcs) - for the movable carriage and the direction of the counterweight
• 10 mm plywood (for the carriage and the plane on which to rest the sheets) - it took 2 sheets, but I made some of the parts from scraps and defective parts during the production process
• Cable (I don’t remember how much I paid for, but they are not expensive, plus there is quite a lot of it left)
• Socket + relay + push-button post (about 700 rubles for everything)
• Fasteners (screws, angles, studs, etc.)

How much did it cost us?

The total came out to around 12 thousand rubles. (I find it difficult to say the exact figure, since something was purchased in stages, some of the receipts were lost and some amount went towards the delivery of spare parts). At the same time, the main part of the amount is the circular saw itself (which can still be used as a hand tool) and the shafts.

What shortcomings were discovered and what would I change?

• Shaft diameter 20 mm. Professional formatters use 40 mm shafts, so it is difficult to bend them when cutting. Why didn't they take 40 mm? To be honest, it was strangled by a toad - one shaft 2 meters with a diameter of 40 mm costs almost 10 thousand rubles. And you need 2 of them (let me remind you that the entire format set cost 10-11 thousand rubles, including the circular). If you decide to assemble it on a furniture rod (for hangers), I don’t recommend it right away - our solid 20 mm shafts bend a little, and the rods will simply bend.
• Wooden frame. The tree tends to “walk” and dry out. Therefore, some bars may bend a little due to changes in humidity. An aluminum frame made from a machine-made profile would cost 30-40 thousand rubles. Simple square aluminum tubes are about half the price, but their bending rigidity is lower than that of a machined profile. In theory, key places can be strengthened with metal corners (we are talking about molded products, not corner fastenings of parts at an angle of 90 degrees). But again, the frame is attached to the floor and wall, and the problem of bending is solved by periodically adjusting the position of the shafts.
• It is still preferable to take laminated plywood rather than simple FC. This will make the sheets travel more fun. Why didn't we use laminated? Because in our warehouse there was only FC, and there was no desire or time to order a laminated sheet separately. Perhaps we will fix it in a future modification.
• The polypropylene bushings for sliding the movable carriage sometimes jam a little and they whistle. Now I would do it a little differently, but I’m showing you exactly how it was during the manufacturing process.
• Instead of shafts with a counterweight, it’s better to look for a cable with a “reverse traction tape measure” (I’m sorry, I didn’t look for the exact name of this unit). It should be no more expensive than my version, but it will be easier to assemble such a design. Plus, the extra resistance in the rollers that I used above the machine will disappear.

PS If you are new to our website and are interested in carpentry, then take a look at what cool things our CNC burner machine Pyroprinter does (this is not paint - it is BURNING):

You can read about the PYROPRINTER machine itself here

FAQ

What is the best way to lubricate the moving elements of the carriage for a consistently smooth ride?

It is extremely rare and mainly for equipment with ball carriage systems that the manufacturer recommends a special lubricant that does not collect dust and sawdust. “Veretyonka” and “Industrial” cannot be used as a worthy alternative, because the dust on them accumulates to a thick consistency.

The only solution is to disassemble the carriage and physically remove all debris. It is strictly forbidden to lubricate the system with “WD” type aerosols. Because this is the main reason why the sealing rubber inserts come off. In the vast majority of cases, the units of format-cutting machines do not require lubrication. Simply blow them off with a stream of compressed air.

Is it possible to customize the format yourself?

Yes, if it is a manual machine. Moreover, for most budget models, monitoring of the accuracy of settings should be carried out constantly. Because of this, independent adjustment may be required quite often (up to daily correction). And each call to a specialist significantly increases the payback period of the machine.

In fact, this process is not the most difficult. Even a novice operator who has no experience in carrying out such work can handle it. To speed up the process and correctly perform the adjustment procedure, it is necessary to determine in advance the position of all adjustment points and prepare a suitable tool. More details about the principles, devices and simplest methods of fine adjustment of mechanical systems are described in the video:

Setting up the operation of electronic units should be entrusted to a service technician with the necessary diagnostic equipment.

Which saws are suitable for the format saw?

Particular care should be taken when using refurbished saw blades (usually sold together with used machines). Overheated, with broken geometry; sharpened without the use of high-precision, highly specialized equipment - all this is a potential threat to the quality of cutting.

New discs are selected in accordance with the specified dimensions (outer Ø, seat Ø) and the characteristics of the material being processed. There are many nuances, each of them is necessarily reflected in the catalogs of equipment manufacturers. Based on the general principles of correspondence between the characteristics of the teeth and the properties of the materials being processed, general rules are formulated:

1. teeth with a positive slope of the working edge are better suited for processing solid wood than others;
2. with a negative slope - suitable for laminated particle boards and aluminum;
3. The more teeth on the disk, the cleaner the cut of hard materials.

What to look for when choosing a “no name” or used machine?

Difficult to eliminate, and therefore not acceptable: backlash in the carriage, violations of the integrity and geometry of the working surfaces.

The package should not be ignored. An unpleasant surprise here will be that for discontinued models, not to mention additional equipment, even original elements from the basic set will be difficult to find.

It’s good if, when comparing the expected load and the machine’s passport data, the reserve potential becomes obvious (high power, wide range of disk revolutions, etc.).