In the previous article we told how you can make it yourself, that is cutting element is a thin, flexible file that is tensioned using a spring. This tool is very convenient for making figured cuts - all kinds of curves, radius saws. However, in a carpentry shop the main requirement is to cut in a straight line under different angles. For such tasks, the above-mentioned machine will be inconvenient, so we bring to your attention a new design designed specifically for even and straight cuts.
Introduction
Classification
There are two main constructive approaches to solving this problem; they are divided by location in space:
- up;
- down.
The first option will be described by us a little later, since at the time of writing this article it is in development at the prototype and design stage, but the second option will be described in this article.
Purpose
This design is quite universal and has a wide range of applications from domestic (at home) to industrial use (carpentry workshops, furniture workshops, etc.). Versatility is determined by the fact that the machine is built on the base, which is common hand power tools and almost every master owns it, as it is compact and multifunctional. With its help you can make blanks from various types materials:
- solid wood;
- plastics
and others.
Advantages
Compared to in a standard way using this device allows you to achieve one thing, but very important parameter, – evenness of the cut. You can saw off quickly and somehow quite simply by placing the workpiece on a horizontal surface, hanging the part to be sawn off, and sawing off. But there is no need to talk about the quality of the cut, no matter who the master is. Our design allows:
- make a simple, even cut (strictly in a straight line);
- trim the workpiece at a clearly specified angle - 90° and other arbitrarily specified angles;
- make a straight saw at an angle to the plane of the workpiece, when it is not perpendicular to the plane of the workpiece, but has a different, preset angle, for example 45°.
Basic design
The device is not complicated and consists of several basic elements:
- base;
- guide;
- swivel stop.
All structural parts are made of plywood or solid wood.
Here's a little background information that might come in handy.
| Nominal plywood thickness, mm | Number of layers of plywood, not less | Sanded plywood | Unsanded plywood | ||
| Maximum deviation, mm | Different thickness | Maximum deviation, mm | Different thickness | ||
| 3 mm | 3 | +0,3/-0,4 | 0,6 | +0,4/-0,3 | 0,6 |
| 4 mm | 3 | +0,3/-0,5 | +0,8/-0,4 | 1,0 | |
| 6 mm | 5 | +0,4/-0,5 | +0,9/-0,4 | ||
| 9 mm | 7 | +0,4/-0,6 | +1,0/-0,5 | ||
| 12 mm | 9 | +0,5/-0,7 | +1,1/-0,6 | ||
| 15 mm | 11 | +0,6/-0,8 | +1,2/-0,7 | 1,5 | |
| 18 mm | 13 | +0,7/-0,9 | +1,3/-0,8 | ||
| 21 mm | 15 | +0,8/-1,0 | +1,4/-0,9 | ||
| 24 mm | 17 | +0,9/-1,1 | +1,5/-1,0 | ||
| 27 mm | 19 | +1,0/-1,2 | 1,0 | +1,6/-1,1 | 2,0 |
| 30 mm | 21 | +1,1/-1,3 | +1,7/-1,2 | ||
Making tooling for straight sawing with a jigsaw
This section will describe step by step instructions for the manufacture of the product. The whole process is divided into three stages of manufacturing structural elements:
- base;
- guide;
- swivel stop.
For production we will need the following materials:
- solid coniferous wood;
- various fasteners (mainly wood screws, furniture fittings, pins, etc.)
and the following tool will also be used:
- Milling machine;
- Circular saw or machine from;
- Drilling machine;
- Grinder();
- Jigsaw with ;
- Various hand tools.
Guide
To make a guide you need to take a board of the following sizes:
It must slide along the guide, so the features of the guide plate (in technical slang - “sole”) are very important.
We mark the guide blank.
Then you need to select a groove with a router, which will serve as a guide along which the jigsaw sole will move during the sawing process.
We make end stops. Then they need to be glued to limit the movement of the jigsaw along the guide, as shown in the photo.
We check the smooth movement of the jigsaw along the guide and if there are defects or burrs that impede the movement, remove them.
Next, you need to make cylindrical bushings to prevent the wood from jamming when clamped with fixing screws. The bushings can be made from an aluminum tube with a diameter of 10mm. We drill holes and press bushings into them. This completes the production of the guide.
Base
The base, by and large, is just a box, which is the basis for attaching the guide and the rotary stop, and most importantly, it raises the entire structure above the level () so that it does not get damaged.
The assembly of the box is simple and unpretentious - the top base is made of the same or solid wood and the sides are made of the same wood. So, we cut out the sides.
And we attach them to the base to form a box, as shown in the photo.
Next, screw M6 or M8 furniture fittings into the drilled holes in the base.
We screw the studs into them and install the guide.
We make a cut in the working groove, as shown in the photo.
We cut out an expanded groove to allow sawing at an angle. Please note that when sawing at an angle, you need a fairly long
We fasten the straight stop with screws, make a hole and install an M6 or M8 furniture fitting to attach the rotary stop. See photo below.
At this point, we consider the manufacture of the base complete.
Rotary stop
The design of the stop is simple and unpretentious; it is a guide with a semicircular element glued to it for fixation on the base.
Install the stop using a bolt of the appropriate diameter. The bolt head can be “placed” in a comfortable handle so as not to have to be used every time wrench. We also secure the guide using homemade nuts made from mortise wing nuts.
At this point we consider the sawing machine ready.
We hope that the material presented was useful to you.
Conclusion
We have made a universal device for straight cut based on a household jigsaw, which should rightfully take its rightful place in your workshop among the tools.
A tabletop jigsaw machine will be useful to every craftsman who cuts out thin parts. However, it is not always possible and meaningful to purchase a full-fledged machine. In that case, get down to business and make it yourself!
The structure of a jigsaw machine - what lies inside?
Jigsaw machines are more of a special tool than a device that is needed by both an experienced craftsman and an amateur who runs a garage. Their purpose comes down to a special task, namely cutting out complex curved contours from sheet materials. A special feature of such machines is the execution of cuts without violating the integrity of the external contour. Most often, sawing occurs on wooden and derivative materials (plywood, chipboard, fiberboard), although modern machines equipped with appropriate saws can also work with other materials, for example, plastic or plasterboard.
Such equipment has found application in the music industry (manufacturing musical instruments) and, of course, in the furniture room. Those who like to make things in their own workshop also buy such units. The device of the traditional jigsaw machine, designed according to all the rules, looks like this: working surface, on which the saw is mounted, hides the drive (electric motor) and the crank structure underneath. The tension mechanism can be located either below or above the machine.
To process a part, it must be placed on the workbench. Many models have the ability to rotate it at different angles to make bevel cuts. Stops and guides on the surface, as well as swivel mechanism may have markings, which greatly simplifies and speeds up the work. The length of the cut depends on the length of the work table - most models are limited to 30-40 cm. Electric motor power is an important, but still far from the most fundamental factor, since the machine has a huge reserve of unclaimed power. For example, for a home workshop or even small production, an “engine” of only 150 W is sufficient.
The crank mechanism is much more important detail, because in in this case It is on this that the quality of transmission of the drive’s torque into the translational and reciprocal motion, directed in the vertical plane by means of a saw, depends.
Standard jigsaw machines are considered to be devices with an amplitude of movement of around 3-5 cm and a vibration frequency of up to 1000 per minute. Many models provide a change of speed mode for different materials. The jigsaw file itself is usually made up to 35 cm long and is capable of sawing material up to 10 cm thick. The width of the files can vary in a fairly wide range - from very thin two-millimeter to coarser ten-millimeter, with a thickness from 0.6 mm to 1.25 mm.
Even the thickest and widest file will easily break if you do not provide sufficient tension along the entire length of the file. Leaf and coil springs are used for this. Quite often such machines are equipped air pump, which cleans the cut from sawdust using a blower, as well as a drilling unit. The latter device is especially useful, because in this case the master does not need to be distracted by the connection electric drill and drilling a hole - everything happens on the working plane of the machine. Of course, you have to pay for convenience!
How to make a jigsaw with your own hands from a manual jigsaw?
On the Internet you will find many different designs homemade machines, but most of them come down to repurposing into this device. By using your ingenuity and watching the video, you can easily make a homemade jigsaw from this tool. The jigsaw only needs a little modification. In fact, it plays the role of a machine drive and a crank mechanism, but the rest needs to be thought out and implemented.
Of course, manufacturers are trying to please consumers in this area as well, offering their own platform options for quick and convenient remodeling, however, in reality only you can make a device that suits your needs. So, the first step is to make a support table, for which they most often use sheet metal. You need to make a beveled oblong hole in it for the saw blade and holes for fasteners (screws with countersunk head), and attach the jigsaw to the bottom of the support table.
This structure can only be strengthened wooden table. You can go beyond this and install guide rails. The convenience of such a device lies in the fact that in addition to performing functions that are not entirely inherent to it, you can always disconnect the drive and with a slight movement of your hand turn it back into a manual jigsaw! If you constantly need this tool for work, it makes sense specifically for the machine - it will be cheaper than spending money on a real machine.
Advantages and disadvantages - we continue to modify!
But such a unit inherits not only the advantages of the tool, but also its disadvantages, in particular, the file is too wide for filigree work, which significantly limits the curvature of the lines. If there is a need for this, there will be a way out. So far, our machine differs from the classic jigsaw unit in the absence of springs that would ensure sufficient tension on the file. But it’s quite easy to build a simple rocker, which on one side will be under the tension of springs, and on the other, fixed to a nail file.
There is another option - to clamp the nail file between two guide rollers, but the first option is still more reliable. Don't forget to turn off the pendulum action on your jigsaw before you start using your homemade machine. There is another design - if your tool is powerful enough, then it can only serve as a drive in a structure of two rocker arms, between which a nail file is stretched. The movement is transmitted through a file attached to the lower rocker.
Machine from a sewing machine - giving a second life to old tools!
If you inherited a foot or hand weapon from your grandmother or mother sewing machine, consider yourself the owner of an excellent jigsaw! Of course, for this you need to “work a little magic” on the machine. First, remove the thread weaving device, which is usually located at the bottom of the machine. There is nothing complicated about it, just unscrew two bolts. Then we knock out the cotter pin and remove the drive shaft leading to the thread weaving mechanism.
Unscrewing top panel protecting the mechanisms, it is necessary to widen the slot in which the needle went. Be guided by the needs and width of the nail file that you will use in your work. Files for a jigsaw of this kind also need to be slightly modified, namely cut to maximum length needles that could be used on this machine. Having ground off the upper teeth and sharpened the lower part to the point, all you have to do is insert the file into the needle holder and test your machine in action!
Here general scheme jigsaw machine operation.
I had a homemade machine, I already briefly wrote about it. Since I am a furniture maker, I made it from leftover LMDF. Cheap and cheerful :). I didn’t care at all about appearance, as long as I worked. And he did a good job! On it I understood all the nuances of sawing from solid hardwood, such as walnut, oak, ash. Everything would be fine, but the drive, and it was a Krees 350W construction jigsaw. I worked for 15 years! The speed control of the drive is “closed”, it turns on immediately to maximum and immediately breaks the file. I couldn’t find a native branded regulator. I have tried all sorts of regulators, dimmers for chandeliers and regulators from the seams. machines, vacuum cleaners. I could not achieve the desired result, namely a wide range of adjustment.
The photo shows the principle of operation of the jigsaw. construction jigsaw transfers oscillatory movements onto the rocker arm, on which the file is in turn attached.
In the end I gave up. The Moor has done his job, the Moor must go. I decided to buy a new jigsaw drive. All Chinese options jigsaws are not suitable, adjustment on them is just a name. In the Makita company store I found what I was looking for. 450 W jigsaw. Wide range of adjustment, and does not scream like Chinese jigsaws! Works quietly!
Here is my new drive, Makita 4327.
I found a new drive, but it didn’t work out to install it instead of the old one, the height is not suitable. I decided that rather than redo it, it would be better to make a new one, taking into account the elimination of the inconveniences identified during the process of working on the old one.
1. Increase the clearance from the file to the frame (on the old one it was 27 cm). For this you need an elongated rocker arm.
2. Increase the vertical stroke of the saw for good chip removal. (on the old one, the saw stroke is 18mm.)
3. Appearance! Schaub was not ashamed to take photographs. :)
And so! the machine is ready!
Here it is my new machine!
The clearance from the file to the frame is 45cm! The vertical stroke of the saw is 30mm! Dream!
Test cutting. The result is excellent! The Makita regulator works great. The machine makes noise like a household sewing machine.
Very fast and quite compact tool, can be incredibly useful for making straight and curved cuts. The appearance and 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 must first understand what makes saw blade 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 is 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
Also, there is another manufacturing option 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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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.
A manual 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 hand 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 an electric motor. Hand jigsaw consists of a housing in which the engine, mechanisms, speed controller and pendulum mechanism are installed (on some models).
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 made of 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 an 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 countersunk screws. 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.