How to make a sawing machine from a jigsaw with your own hands + photos and videos
An electric jigsaw is no longer a rarity or even a luxury, and it is almost always in the toolbox of almost all home and even more professional craftsmen.
It is comfortable, helps to cut various materials, and is also relatively safe. The electric jigsaw is used to cut curved shapes, closed or those that have a complex configuration.
It will be indispensable for most home improvement work, as well as for the construction of plasterboard structures, various types and purposes of boxes and other works.
But in some cases it is extremely difficult or even inconvenient to use a hand tool to perform work - poor visibility of the cutting line will interfere, it becomes necessary to hold the workpiece with both hands and other.
But the main problem with a hand jigsaw will be the sideways movement of the file, and this is especially evident when cutting materials with a large thickness, as well as a small radius of curvature. In this case, a sawing machine from a jigsaw will not be superfluous, which is easy to do with your own hands and even a novice master can cope with this task.
Such a jigsaw-type machine is required in order to make straight or curved cuts of sheet materials along pre-marked circles, contours or guides. Unlike hand tools, in which the saw will be fixed at only one end and retains its shape only due to its own elasticity, on jigsaw machines the saw will be fixed on both sides. Such a machine can replace a lot of devices, and be desktop, woodworking, sawing, and it can also be made on the basis of a drill and milling cutter, circular saw and other things.
The main structural elements can be called:
An electric jigsaw is able to successfully replace the crank mechanism, and set in motion a frame with a file. There are even simpler designs in which the electric jigsaw will simply be attached upside down to the work table downward, and the file will either hold its position during operation due to its own elasticity, or will be fixed from above by means of guides / spring-loaded bracket that moves with them when working.
This will make it possible to reduce the loss of power while driving on the frame, but you will need to use an extended type of saws, which are not often found on the market.
The main advantage of the jigsaw-type machine will be the ability to perform an accurate cut, as well as no drift of the file to the side.
Moreover, the advantages of jigsaw machines over hand tools will be:
Along with this advantage, there will be one more thing - there will be no need to organize a workplace for cutting, because the machine will be located with the appropriate plane for this.
Please note that along with many advantages there are also disadvantages, namely that it will be difficult or even impossible to cut out internal parts, only cutting along the outer contours.
But they are usually designed for electric jigsaws from certain manufacturers, and also will not work for all other devices. Moreover, the cost of such platforms is often much higher than the cost of the tool.
For this reason, it will be much easier to make the machine with your own hands. The basis for such a machine will be a desktop. It was experimentally found that sheet metal tables were able to demonstrate the greatest efficiency - they are durable, and also provide excellent installation accuracy, frequent replacement and reduction of the working length of the saw blade are not required.
The electric jigsaw is attached to the table through the holes to the reference plane, and if necessary, it will be easy to detach and use it in a standard way.
The work table must be installed on the bed. It can be made of natural wood, chipboard or other materials. The main requirement will be strength, ease of access to an electric jigsaw to a size convenient for the master, or rather height. A rocker arm should be installed on the end of the table, to which the second end of the saw blade with a tension device will be attached.
The most common option would be a regular spring, which will tension the files and prevent the sawing material from being pulled to the side when the direction of the cut is suddenly changed. The manufacture of such a unit will be one of the most difficult and important stages of the work, because it will depend on how high-quality and clean the cut will be, as well as its size of load on the mechanism and the electric motor of the jigsaw.
There are two versions of the tensioner design:
Both the first and second options are popular, have their own advantages and disadvantages, and the choice is usually made in favor of the option that is simpler and more accessible in technical terms.
Next, we suggest that you consider the procedure for creating a jigsaw type of machine. The structure will be a work table and a jigsaw fixed from below. The rocker arm will be made of a rigid, reinforced strut that is equipped with a spring-loaded movable arm. This option will be considered the most reliable and affordable, as well as devoid of unnecessary parts and assemblies.
For clarity and simplicity, it is recommended to sketch out working drawings, which will make it possible to clarify certain design features and answer questions that arise regarding the size, connection points and other details of the assembly process.
The creation of a machine can be divided into main stages, of which there are only 3, and we will consider them separately.
Before proceeding to the direct manufacture of a sawing machine from a jigsaw with your own hands, you should make a certain preparatory campaign. First you need to make a special adapter in order to install the file. In most jigsaws, the seating end of the saw blade is inserted into a socket and clamped with a screw.
The cutting body of the machine will be a longer and thinner saw, equipped with holes at the ends, which are usually put on special pins (or through which screws for fastening).
For this reason, you will need to make an adapter, and its lower part should copy the shank of a standard saw for the jigsaw of your choice, and the upper part should be equipped with a hole for a nut and screw, which will attach the adapter to the machine saw.
Here, the procedure will not be limited by anything - someone grinds out a part of the required shape from a metal plate, and someone takes a piece of a finished file with a shank and welds a steel washer to it with subsequent processing for accuracy.
Moreover, you will also need to prepare all the necessary materials and tools, including:
- Electric drill and a set of drills.
- Angle grinder.
- Welding type inverter and electrodes.
- Pieces of chipboard or plywood for bed and work table.
- Connecting angles.
- Fastening elements (bolts with nuts or self-tapping screws).
This list is not 100% exhaustive as additional materials or tools may be required depending on the case.
So, the first step is to make a working table, surface.To do this, you need to saw off a piece of plywood or chipboard of the selected size. There are no special restrictions, but you definitely need to take into account the size of the room in which your machine will stand. A table that is too small in size will definitely not be convenient for working with large products, and the extra table space will take up a lot of space in a workshop or room.
As a rule, when choosing the size of the worktable, you should also be guided by the size of the parts that you plan to process on the machine.
Holes should be made on the table for attaching a jigsaw and for a file. To do this, you will need to unscrew the sole from the tool, attach it to the table and mark the centers of the holes for the bolts of the connections.
Please note that the connecting bolts that fix the electric jigsaw on the working surface must have a countersunk head so that they do not protrude from the plane of the table and do not exactly scratch the workpiece during work.
Another important step is to create a rocker arm. For this you need a movable arm and a stand.
For the stand, take a profile pipe that has a rectangular cross-section and weld the support platform in the lower part. Its size must necessarily ensure the immobility, reliability and stability of the rack when working under load. The height must necessarily correspond to the length of the file when it is maximally raised and with a small margin for the size of the fastener. The best option would be that in the middle position of the file, the movable lever was in a horizontal position.
The movable element will be a beam that will be mounted on the upright using pivot joints.
The length of the front part will necessarily ensure that the assembly for attaching the saw blade is located exactly above the desired element of the electric jigsaw. The back of the arm will be connected to the spring, which in turn will provide tension. Next, you should make a tension knot. It will be a normal spring that needs to be tightened with an adjusting screw. It should be attached to one end of the spring, made a special loop on the bed and tightened with a washer and nut.
Please note that vibration can cause tensioning nuts to loosen and loosen tension, so it is worth fixing everything for sure with a locknut.
Assembling a sawing machine from a jigsaw with your own hands is not something complicated. Here you need to perform the following actions:
If you have performed the calculations correctly, the file will move exactly vertically and without yawing along the sides. It is recommended to check the progress of the jigsaw before starting the jigsaw and make sure that no unexpected situations are expected.
When working with a jigsaw machine, follow these rules:
- Keep your hands away from the moving saw.
- Do not try to stop the lever or the saw blade with your own hands.
- The cutting attachment can only be replaced after the jigsaw has been completely stopped.
- Do not use too much force when feeding the workpiece to the cutting body.
- Do not work with thick workpieces.
Moreover, it is worth remembering about the rules of fire safety and always after the end of work, remove the plug from the socket.
Making a jigsaw machine with your own hands will not present difficulties, but not all craftsmen have a need for it. Usually such devices are used by people who do a large amount of work and need optimal conditions.
Design features everyone chooses according to their preferences and considerations, there are many options. Product safety and quality will directly depend on the degree of care and accuracy of assembly.
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