Since childhood, we have been familiar with the technology of sawing with a jigsaw. The principle is simple - a stationary part is placed on a stand with a technological cutout, the cut is made by moving the saw. The quality of work depends on the steadfastness of the hands and the skill of the worker.
In this way, you can literally cut lace from thin wooden or plastic blanks. However, the process is labor-intensive and slow. Therefore, many craftsmen thought about small-scale mechanization.
A simple design from the last century
More in the magazine Young technician“Drawings were offered on how to make a jigsaw machine with your own hands. Moreover, the design does not involve an electric drive; the drive operates from muscular force, like a knife sharpener.
The machine consists of main parts:
- bed (A)
- work table (B) with slot for canvas
- lever system (B) for holding saw blade
- flywheel (G), which is the primary drive pulley
- crank mechanism (D), combined with a secondary drive pulley, and driving the levers (B)
- pedal assembly (E) with a crank mechanism driving the flywheel (D)
- saw blade tensioner (W)
The master uses his foot to move the flywheel (D). Using a belt drive, the crank mechanism (D) connected to the lower arm (B) rotates. A file is stretched between the levers; the degree of tension is regulated by a lanyard (G).
With a well-balanced flywheel, sufficient smooth running of the saw blade is ensured, and such a homemade jigsaw machine allows you to massively cut out the same type of workpiece, saving time and effort. In those days, jigsaw files were produced in the form of a flat, unidirectional strip.
Therefore, to obtain patterns of complex shapes, it was necessary to rotate the workpiece around the canvas. The dimensions of the workpiece are limited by the length of the arms (B).
From a mechanical jigsaw to an electric one one step
The foot drive cannot provide real freedom of action and uniformity of the saw stroke. It makes more sense to use an electric motor for the crank mechanism. However, if you use a tabletop jigsaw occasionally, there is no point in making stationary structure with its own motor.
You can use home power tools. For example, a screwdriver with a rotation speed controller.
The materials used are literally scraps of wood and old trash. The only critical part is the bed. It is better to make it from durable plywood with a thickness of at least 18 mm.
We make all connections using wood screws; the joints can be coated with PVA glue. From the same material we assemble a support pedestal for the lever rod. The design of the support should not have any play; the subsequent accuracy of the entire machine depends on its strength.
The idea of creating a homemade jigsaw is most often due to the disadvantages that a factory-made one has hand tool. You can make a small one with your own hands table machine, which will include a pusher, a reciprocating motor, and a saw tension system. In this case, you do not need complex drawings - once you understand the essence, it is easy to achieve the result.
The desire to create a homemade jigsaw may arise for several reasons:
- There is no power supply in the workshop, but it is possible to use the engines internal combustion low power.
- There are pneumatic motors, but the compressor power is not enough for a serial tool.
- The electric motor is powered by batteries or solar panels, the power of the source is not enough to use the power tool.
- It is required to obtain saw motion parameters that are unattainable using a commercial tool.
Designing a jigsaw is not difficult. Typical structure looks like that:
The installation is easy to adapt to any torque source. A pair of pulleys (one is located on the engine shaft, the other drives the crank mechanism) allows you to vary the gear ratio, reducing the load on power unit and allowing you to get the required speed (they are also responsible for the number of saw strokes per minute) on the actuator.
A machine built according to the above diagram may have the most different configuration, the material of manufacture is also selected individually. An example of a finished installation looks like this:
Disadvantages of a manual jigsaw
Hand jigsaw designed to form straight cuts. In this case, as the rollers, rod, and pusher wear out, the saw may wobble, deviate from a straight line, and change the angle of attack. Regardless of the quality of the tool components, the following features are always present:
- When the saw becomes dull, deviation from a straight line is observed when cutting material of uneven density (for example, low-quality chipboard). The saw is capable of leaving the cutting line when it encounters a knot in the wood.
- When trying to make a curved radius cut, you can observe the following picture: the upper cutting line, which the worker follows, follows an exact trajectory, the lower one deviates, goes to the side, the radius becomes larger. The higher the wear of the tool and the lower the sharpness of the saw, the more pronounced this phenomenon is.
- Some materials cannot be worked using a pick-up or bottom feed of the saw. The carpenter is required to move the tool forward extremely evenly, which is impossible to do very accurately; as a result, the saw runs out along the entry and exit path.
It is even more difficult to work with thin ones intended for figured cuts saws. If there is no practice, achieve good result quite difficult, especially on thick slabs or wood materials. Let's look at how you can make a carpenter's job easier and the result better.
Standard solutions
The machine is made from a manual jigsaw based simple table . This device is common and mass-produced; samples can be seen in the photographs below.
The mechanics of work are simple:
- Jigsaw machine clearly fixes the tool, ensuring that there is no influence of the human factor (the hand can move the jigsaw unevenly).
- The presence of a support allows you to move the device without deviations along the trajectory.
With the help of a table, jigsaws begin to cut in a straight line, but the capabilities of such a device are limited. If you remove the side fence and try to guide the workpiece, forming a curved cut, the same problems of saw deflection arise. The problem can be solved by using a simple saw, rigidly fixed with a pair of rollers. Making curved cuts is now convenient and fast. What homemade and industrial products look like of this type shown in the following photos.
Tension devices for curved cuts
To perform very thin and precise shaped cuts, you can make a machine from a jigsaw with a saw blade tension system. The idea of creating it yourself is as follows:
- Very used thin saw, ideally for a manual jigsaw.
- A clamp is attached to the rod of the power tool, which will tighten the cutting blade.
- The trajectory stabilization system will regulate both one freedom of movement and two (horizontal and vertical).
Used as a tension block hand jigsaw clamp, to which an adapter is made, which in turn is inserted into clamping fixture power tool rod. To ensure adjustment of one freedom of movement, a pair of angles and a bolt are used. The result of the idea implementation is presented on next photo.
The saw provides clearly vertical movement, good tension can be created, but there is a mandatory runout in the horizontal direction. The canvas comes with a pick-up and does not move in a straight line.
The development of this idea is in the next photo. Here the part that fixes the trajectory moves, and the metal clamp provides structural rigidity and mechanical resistance.
The system is stabilized in two degrees of freedom, the cut made with its help is neat and precise. By using a diamond-coated cord for a hand jigsaw, you can cut glass without creating messy chips on the edges.
Accessories for extremely delicate work
If you need to work extremely delicately and slowly, you will need to reduce the force on the cutting blade while maintaining strong tension and precise movement of the file. For this, a homemade jigsaw is equipped with spacer devices with long shoulders.
In this case, the power tool does not operate in the cutting zone, but at some distance. This allows, depending on the wishes of the carpenter, to regulate the force, speed and amplitude of movement of the saw. One of the options for implementing the idea is shown in the following photo.
Depending on the needs of the master, the structure can be made of steel, have additional fixing zones, and the power tool cannot be installed rigidly, but with the ability to move within its support beam.
In practice, such solutions are rarely used. For fine work, which are carried out constantly, it is much more profitable to purchase a specialized band saw, which will ensure quality and productivity.
As can be seen from the presented designs, a jigsaw can even be made from sewing machine having a moving rod.
A jigsaw allows you to quickly and efficiently cut wood. consists of a working surface, stands, motor and spindle assembly. Some devices are made on stands. Clamps are quite often installed on the side of the work surface. It is also worth noting that the models differ in power. The manufacture of a jigsaw machine can only be carried out if the instructions are followed.
Desktop devices: expert reviews
If you believe the reviews, then making a desktop modification is very simple. First of all, a stand is prepared for work surface. Its width should not exceed 30 cm. It is more advisable to select a single-phase motor with a maximum voltage of 220 V. A homemade jigsaw machine (desktop) produces an average operating frequency of 55 Hz.
Reviews from experts say that it is better to use yews made of steel; if desired, you can cut them yourself. The file is installed on a spindle assembly, which is attached to the stand. Many models use a latch that acts as a stop. To secure the file, a small screw is used.
Models with legs
If necessary, you can do this yourself. Modification drawings include frames different sizes, and spindle units are usually used with guides. Many models are made on a wide bed. Legs can be installed from tubes. There are also machines with plates. After cutting out the working platform, you should work on the spindle assembly.
If we consider devices with control units, then the model will require a controller. It is more expedient to use a 220 V commutator type motor. Yews are installed on jigsaw machines rotary type. The direction must be welded to the edge of the plate. File in in this case must be securely fixed. Optimal height spindle assembly is 2.2 cm. At the end of the work, it is important to start installing power cable and connecting equipment.
Reviews of devices with wide frames
Professionals are able to assemble a jigsaw machine with their own hands. Device drawings indicate the presence of wide stops. However, first of all you need to install the bed. If we consider a simple machine, then the lock for modification can be selected of a small length. Reviews from experts indicate that two racks are enough for the model. To assemble the machine it is used welding inverter. The spindle assembly itself is installed in the central part of the working platform. The hole for the file can be made with a milling cutter. It is also worth noting that experts do not recommend using two-phase motors.
Compact modifications
By following the instructions, you can assemble a compact jigsaw machine with your own hands. Device drawings include double racks and narrow frames. Beds are used with a low profile. Many models have a spindle assembly without a holder. In this case, the guides are installed to a short length. For self-assembly For models, it is recommended to first select a high-quality frame.
Additionally, a clamp is soldered under the working plate. To reduce vibration levels, you can use a pad. Regular glue is used to fix it. The file for modification should be selected with a small thickness. Optimal distance installation of the central unit is 14 cm. At the same time, the width of the platform is on average 17 cm.
Jigsaws 2 kW
If you wish, you can make this jigsaw machine with your own hands. Drawings for assembling the modification are very easy to find. As a rule, frames are used with a width of 35 cm. The thickness of the plate should be about 1.5 mm. The hole for the file must be made before installing the central unit. If we consider models without stops, then the frame is used with a low profile. It is also worth noting that it is more advisable to install the spindle assembly on a lining.
A casing is used to reduce noise levels. Many models use multiple stops. In this case, the unit is installed at a height of 10 cm. It is better to fix the file on the plate. The clamp can be used screw type. After fixing the central unit, the motor is installed. For modification of this type, a device with a single-phase unit is suitable.
3 kW models
It’s quite easy to make a 3 kW desktop jigsaw with your own hands. Experts recommend using racks with wide stops. The clamps need to be installed only after the central unit. The modification file can be adjusted to 1.2 mm. Some experts make the hole after installing the frame. In this case, the supports are soldered to the sides of the table.
Next, it is important to evaluate the spindle size. It is more advisable to use the motor with a protection system and casing. It is also worth noting that collector devices that operate at a frequency of 45 Hz are very popular. They have low energy consumption and do not overheat. Holders are used to secure workpieces. The optimal spindle height is 15 cm. It is also worth noting that there are models with tuning plates. A flywheel is used to control the stand. A conventional controller is available to install the control unit.
How to make a 5 kW device
Having prepared several stops, you can make a jigsaw machine with your own hands. Reviews from experts indicate that 5 kW models are well suited for longitudinal cut. Before starting work, all necessary tool. You will need a saw and welding machine and cutter. It is more expedient to assemble the frame for a jigsaw from steel plates with a thickness of 1.3 mm or more. You need to immediately provide a place for the motor. The frames in the devices are installed with a high profile.
At this stage, you can immediately cut a hole for the file. The plug assembly must be mounted on the top of the plate. Additionally, it is worth noting that the file will require a large holder. If we consider simple model, then the racks can be installed on the sides of the frame. Yews are of the rotary type. There must be a stand at the top of the frame. A small casing is fitted under the motor. On average, the width of the frame should be 35 cm. If we consider professional models, then they use adjustable clamps.
Modifications for two quills
How to make a jigsaw machine with your own hands? The model with two quills is assembled only on wide frame. First of all, the plates for the bed are cut out. If we consider a desktop modification, then it is more appropriate to install the control unit at the top of the device. Optimal width frame is 45 cm. In this case, the spindle assembly is installed behind the stops.
There must be provision for racks. Many models use transmission units. In this case, motors are only suitable for commutator type with a frequency of 30 Hz or more. The file is installed as standard in the holder. The optimal height of the spindle assembly for models is 35 cm. Quills for adjusting the bed are used with flywheels.
Models with three quills
It’s easy to make this one with your own hands based on a single-phase motor. Tools should be prepared in advance. Many models are equipped with frames with four stops. They have a long length and a high profile. It is also worth noting that spindle units are selected from. At the beginning of work, it is very important to calculate the length of the frame. If we consider ordinary spindle units, then the stand for them is prepared in a short length.
The central support must withstand heavy loads. A welding inverter is used to install the plates. The motor will require a casing that will significantly reduce the noise level of the device. The saw for modifications of this type is suitable for 1.2 mm. With a power of 3 kW, a device with three quills will produce a frequency of 55 Hz. To fix the flywheels, brackets are needed.
How to make a jigsaw with your own hands? A jigsaw is a saw blade that makes a reciprocating motion. Currently, this tool can be motorized, manual, or foot drive. It is difficult to unambiguously classify jigsaws. Let's look at their main varieties.
A jigsaw is designed for cutting out various parts from metal, wood, plastic, and ceramics.
Hand jigsaw consists of a saw blade and an elastic frame (bracket). The frame has special clamping devices for fixing the canvas. The frame has a horseshoe shape.
The advantages of this jigsaw are the accurate and clean cut of the workpiece, the ability to cut out various shapes (multi-beam snowflake). However, such a tool requires high professionalism and a strong hand.
Jigsaw machine type(desktop) is an evolutionary continuation of the manual jigsaw. It has all the advantages of a manual jigsaw and none of its disadvantages. It allows you to cut complex internal holes without cutting the outline.
The only downside is that this quality tool costs a lot of money. Structurally, it consists of a base (the workpiece is attached to it), and levers are installed at the top and bottom, at the ends of which there is a thin file.
The levers are driven by a pendulum with electric motor. A manual jigsaw consists of a housing in which a motor, mechanisms, a speed controller and a pendulum mechanism (on some models) are installed.
A motor, a speed controller and a gearbox are installed in the housing to convert rotational movement into reciprocating.
There are two common types of housing: D-shaped (silhouette similar to an iron) and L-shaped. These tools can be used to cut thick and hard workpieces.
Every master who respects himself and his time has this device in his arsenal. The advantage is that access to back side blanks. The disadvantages include the impossibility of cutting out complex parts of small shapes.
Purpose of the jigsaw
The tool is designed for figured sawing parts from thin sheet materials, be it wood, plywood, steel, non-ferrous metals or ceramics.
Only a jigsaw can make a curved cut of a complex part. That is why it is so popular among carpenters, furniture makers and model makers. Moreover, in household This indispensable tool. A jigsaw is mainly used for sawing wooden products. It makes it easy to embed a sink or electrical panel into the tabletop.
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Methods for making a jigsaw
You will need materials and tools:
- engine;
- file;
- chipboard sheet;
- self-tapping screws;
- screws;
- table or workbench;
- clamps.
The most common are three methods of making this instrument. The first one is very primitive: you need to attach electric jigsaw To flat surface, for example, to chipboard sheet, having previously made a hole for the file.
The power tool should be secured to the chipboard using self-tapping screws or screws with countersunk head. It is very important to securely fix the jigsaw to the tabletop.
The finished device is attached to a table or workbench using clamps. This device is made quickly, in about an hour.
But this design unsuitable for working outdoors or in the absence of a suitable table. Eliminating these shortcomings will lead you to next model homemade electric jigsaw.
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The second method of making a jigsaw
Materials and tools:
- engine;
- box;
- jigsaw;
- additional guide for the file;
- table or workbench.
This option is quite simple. You need a box, a jigsaw, and an additional guide for the file. You can make a box 40 cm wide, 30-40 cm long and 30 cm high. The height of the table will depend on the height of the jigsaw handle. Next, the tool itself is inserted into the structure, and then you can work anywhere. For ease of storage in a small workshop, the box should be made collapsible. This will save some space.
The disadvantage of this design is the uneven cut. This is due to the fact that the blade is secured on only one side. In the process of cutting a thick workpiece, a long blade (up to 40 mm) periodically deviates along the vertical plane. This defect can be eliminated by fixing the saw blade.
You can fix the saw blade using an additional guide, at the end of which a hard plastic with a cut or a ball bearing is installed. In addition, it is impossible to make cuts with such a tool. complex shapes With high quality. This is a consequence of using a standard electric jigsaw blade. This minus is eliminated by improving the machine now.
Very fast and quite compact tool, can be incredibly useful for making straight and curved cuts. Appearance and the functionality of the jigsaws sold are impressive, making one believe in the incredible complexity of the design of these devices. In fact, to recreate such a mechanism, it is enough to understand the principle of its operation, have instructions and the desire to do something with your own hands. It is not at all necessary to be an expert in technology with many years of experience (although this quality will not be superfluous). Next we will carry out detailed analysis average jigsaw model with drawings, and we will provide two detailed manuals By self-production similar tool.
How does an electric jigsaw work?
Although the device of a jigsaw is not particularly complicated, its mechanism has certain features that require familiarization. To understand how to make a jigsaw, you first need to understand what causes the saw blade to make reciprocating movements. For the clearest understanding of the principle of operation of the device, we will present the main components that make up the mechanism of the instrument and describe their interaction with each other.The basis of any electric jigsaw is the following components: an electric motor, a gearbox and a rod with a saw blade clamp. To the secondary ones, but no less important elements, include the start button, support roller, cooling fan and soleplate. As additional functionality, many models have a pendulum stroke, a dust collector, lighting and a laser guide. We will not touch upon the operating principle of the latter, and will move on to a description of the interaction of the main elements of the mechanism.
The high-frequency movements of the jigsaw saw blade originate from an electric motor, started by pressing a button or directly from the network. Rotation is transmitted along the shaft to special mechanism“gearbox” with an eccentric that interacts with the rod, forming a reciprocating movement. The mount installed at the end of the rod holds the saw that makes the cut. To minimize the load on the rod with the gearbox, the rear edge of the saw blade rests against the support roller. In this way, all components of the device are involved to perform the main task of sawing all kinds of materials.
Electrobolic drawings
A detailed study of any device is much easier when there is detailed diagram with a description of each element. Thanks to the exact names of parts with dimensions, general idea the operating principle of the mechanism becomes more clear. Below we have placed several detailed illustrations, since assembling an electric jigsaw with your own hands with detailed drawings is much easier than relying only on your understanding of the design features.
We hope that the presented diagrams will completely clarify your understanding of the structure of such a mechanism and provide useful food for thought in assembling your own jigsaw.
Making a jigsaw with your own hands
For a craftsman who understands the principle of operation of any mechanism, it will not be difficult to reproduce it, especially if he has detailed instructions. The bicycle has already been invented, and to make it yourself, it is enough to have a kit available necessary details and tools. The guide below will demonstrate in detail how to make a jigsaw with a complete listing of the elements and tools required for the job. The product being created is not a stationary device, but a mobile saw with an electric drive. The device has not much power, but it is enough to cut wood up to 5 mm thick.
Required materials:
- Wooden block - 150x75x25 and 75x25x25 (width, height, thickness in mm)
- Metal plates – long and rectangular (as in the photo)
- Jigsaw blade with U-shank
- Electric motor RS-540 12V (any similar one can be used)
- Circuit closing button
- Nozzle gas stove
- Bicycle spoke
- Plastic circle with a diameter of 260 mm
- Plywood - 120x50x5
- Set of self-tapping screws, bolts and nuts
- Hacksaw for metal
- Triangular file
- Pliers (2 pcs)
- Screwdriver or drill with a set of drills
- Metal scissors
- Pencil
Assembling the jigsaw will begin by cutting out the handle from a larger block. To do this, just cut it, giving the rectangular board an L-shape, as in the photo. The dimensions of the cut part are set “by eye”, based on the preferences and size of the operator’s hand.
One of the most important nodes The device, which serves as a movable rod and clamp for the saw blade, requires increased reliability. This element is made of a long metal strip, 1 mm thick. At the end, trace the outline of the file shank, after which a notch is made with a triangular file to create a pressure plate. Part of the metal strip is bent with pliers along the contour of the shank, after which a file is installed in the improvised mount and drilled through hole for additional fixation with a bolt.
The saw blade mounted on the rod must be connected to the device using a guide. This part is made of metal plates rectangular shape. Using pliers, bend the center of the plate into a flat groove for the rod with side mounting lugs. To prevent abrasion of the wood and facilitate the movement of the saw, we apply a similar piece of metal to the front side of the prepared handle and screw it together with the groove. As a result, it should be next construction.
At the end of the rod, we carefully bend the metal until we get a kind of loop into which the end of the crank mechanism lever will be inserted.
We screw the previously sawn-off wooden rectangle to the top. It will serve as a stand for the motor, creating additional space for installing crank elements.
The conversion of engine rotations into reciprocating movements will occur using a simple mechanism made of a round plate, a gas nozzle and a weight-bearing spoke. In the center of the circle, drill a hole with a diameter equal to the threaded part of the nozzle (so that it fits as tightly as possible). Next, install the nozzle in place and fix it using epoxy resin. We put the dried structure on the electric motor shaft. If the nozzle hole is too narrow, you can widen it with a drill of the required diameter. Between the center and edge of the circle, drill another small hole with the diameter of a bicycle spoke.
Unfortunately, it is not possible to find the upgraded gas stove nozzle with a side screw used in the instructions everywhere. If only an ordinary one is available, it can be fixed on the shaft using tin and a soldering iron, as in the photo below.
Having combined the motor with the round plate, it's time to turn it into a real crank. To do this, take a bicycle spoke and use pliers to bite off the curved head and threaded part to get an even metal rod. Next, we retreat 10 mm from one end and bend it at an angle of 90°. We insert the bent part into the previously prepared eye in the rod and lift it up so that the saw fastening screw rests against the metal plate.
The accuracy of the next step is most important, since the amplitude of movement of the saw depends on it. It is necessary to determine the exact location for the second bend of the rod so that the crank and rod connected by it work most efficiently. To do this, we place the engine in the place of the future mounting and place the outermost hole of the circle upward. Next, we bring a rod to the hole, the opposite edge of which is inserted into the eye of the rod raised all the way and mark the place of the bend. We bend it at an angle of 90°, insert it into the hole of the circle and check the functionality of the mechanism. If the crank works as it should, fix the motor in place with a metal plate.
The next structural element will be the installation of a sole, which will also serve as a support for the saw blade. A similar part can be made from ordinary plywood, 5 mm thick. In the center of one of the ends, we make a small cut (20-30 mm) and pass the file of our jigsaw into it. We fix it with a self-tapping screw with a countersunk head.
The final stage will be installing the start button and connecting the wires. The button can be displayed in any place convenient for you. The author considered it necessary to place it on hot glue in the corner of the handle. We create a basic electrical circuit (motor-button-network and motor-network) and connect it to a 12-volt power supply.
For a smoother ride, it is recommended to lubricate the rod with oil.
A more visual demonstration of this instruction, but unfortunately without comments, can be seen in the video below.
Homemade jigsaw for polystyrene
Assembling a fairly convenient and reliable device for cutting thin wooden blanks and polystyrene. This method almost similar to the previous one, but has a more functional design. Compose detailed description How to make this electric jigsaw with your own hands is not necessary, since the design of the device is similar to the previous assembly. We will bring full list necessary materials and manufacturing tools.
- Plywood 200x200x5 mm
- Wooden block - 120x50x50
- Spatula or sheet of metal, 1 mm thick
- Metal terminal for connecting wires
- Metal rod (spoke)
- Hacksaw blade
- Electric motor (DC) 12 volt
- A piece of thin, flexible plastic
- Fastening metal corner
- A piece of PVC pipe as a handle
- Contact closure button
- 12 volt power supply with DC plug
- DC power connector
- Self-tapping screws, bolts and nuts
By instruments:
- Needle file
- Metal scissors
- Pliers
- Drill or screwdriver with a set of drills
- Core drill for wood with a diameter of 44 mm
- Soldering iron
- Thermal gun
There is also another option for making a homemade jigsaw. Principle of operation of this product, similar to the previous two, there are some nuances in the design. We hope that the following video will be useful and give you fresh ideas to create your own instrument.
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