Introduction: $10 DIY Dremel /RotaryTool

Picture of $10 DIY Dremel /RotaryTool

A Rotary Tool is perhaps the most used tool. It can Cut, Grind, Sand, Polish, Engrave with the Different types of bits.This small little DIY Dremel is easy to hold and cut metal, Acrylic, Drill PCB. Sand And Engrave too.
It is Easy to make and is very powerful.
It can work both with an adapter or with any battery Lipo, Lead Acid.
Mostly It will come really handy for future projects.

This project is made for the build a tool contest , so if you like it do vote for it

You Can Also Watch the Video [ Play Video]
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Step 1: List

Picture of  List


Drill Chuck ::

Drill Chuck Alternate link :

DC Motor: :

Momentary Switch :

18 AWG wire :

Epoxy glue :

M3 bolts


Wood Cutting disk :

Abrasive Cutting disk :

Drill bit :

Sanding Bit


3D Printer Used

DIY Soldering Helping Hand

DIY Fume Extractor


Step 2: Designing the Enclosure

Picture of Designing the Enclosure

So Basically I started by designing the motor enclosure, I took a measurement of the motor diameter, the motor height, and motor shaft diameter.Then Using Fusion 360, I Started making a basic Sketch.
I then added the switch mount hole and air flow holes.
Now if you are new to 3D designing Instructables give you a good start with their instructable classes.
Jonathan Odom made a really good tutorial in it.

Step 3: 3D Printing the Enclosure

Picture of 3D Printing the Enclosure

STL Files
I First sliced the STL using Cura with the following Setting

Temperature 195 C

Speed 85 mm/s

Raft & Support Disabled

Layer height 0.2

Infill 20%

The Print time took around 2 Hour 30 mins

Step 4: Tinning Wire

Picture of Tinning Wire

I Used 18 AWG for the project as it will handle more current.Now before starting to solder it, we need to tin the wires.

To tin a wire, apply the tip of your iron to the wire for a second or two, then apply the solder to the wire. The solder should flow freely onto the wire and coat it (if it's stranded wire the solder should flow into it, and fill the wire). You may need to snip the end off afterward, particularly if you have put a little too much solder on and it has formed a little ball at the end of the wire.

Step 5: Soldering the Motor

Picture of Soldering the Motor

The Motor I am using can handle voltages up to 24 V. This motor is a 550 motor but I have salvaged it from an old printer long ago.The only difference is has a brass gear on the shaft. Anyways I tinned the motor terminal first with a little solder, And then soldered the tinned wire, from the last step. Btw the whole motor easy holds by the helping hand.

Step 6: Soldering the Switch

Picture of Soldering the Switch

The Next step is to solder the switch. Now the Switch is used, turn on and latched to the on state until it is pressed again .You can also use a momentary switch.
Taking the wires out from the hole I started to solder the wired to the Switch.
I used some heat shrinks to prevent shorts.
Then I fixed the switch in position .

Step 7: Applying Glue

Picture of Applying Glue

I used A bit of epoxy glue to fix the motor in the place. To apply the glue we need to prepare it at first by mixing equal amounts of resin and hardener. The bond is really tough but it takes the time to cure, hours .apphours.
Once the glue had cured it is a hard bond.Alternately you can use some m3 bolts to fix the motor

Step 8: Fisnishing Up

Picture of Fisnishing Up

I then put the motor in the enclosure, enclosure took the wire out of end part and then closen closure with the end cap. I Also Drilled and added the nuts later just be on the safe side befoe the glue dries. Then I fixed the chuck.I took some care to make sure the chuck fits perfectly aligned .After the glue cured it was time to test the Tool

Step 9: Performance Test

Picture of Performance Test

Can it Drill?

Yes, it can drill.Tested on plastic wood and PCB

Can it Cut?

Yes, it can Cut Metal bolts, Nails, and Screw.
It can also cut Plastic and Acrylic.

It can also cut wood, but I have to test it with a new Saw blade.

Can it engrave?
yes, it can engrave easily.
Tested on Plastic.

It can also be used to sand, buff and polish .you will be seeing it more in future projects.
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patrick panikulam (author)2017-10-23

Hi there, can you tell me more about the power supply you used?, It's voltage and current
If it's smps or transformer based?

SherylinRM (author)2017-03-17

Confused about the black stuff used to put the chuck on the motor.

Also how were you able to line it up etc?

The adding of the chuck is the only thing I did not understand both watching the video and reading the text.

Voted for you.

geekrex (author)SherylinRM2017-03-20

Sorry for late reply
I use some Indigenous stuff but you can buy a mount it comes with chuck most time.

SherylinRM (author)geekrex2017-03-20

Ok thanks :)

BoboTheEpic (author)2017-03-15

This is by far the most sturdy looking hand-made rotary tool I've ever seen. Mostly owing to the fact that you didn't use a toilet roll tube to make the case! I really like the look of the end product, and any tool you make yourself is so satisfying to use.

geekrex (author)BoboTheEpic2017-03-20

Thanks Alot

kavish laxkar (author)2017-03-15

Great Going.:D

gcai_fwb (author)2017-03-14

very creative but I can buy a 80 pc rotary tool kit from Harbor freight for $10 so why would I spend more $ and my time to make this? just wondering?

geekrex (author)gcai_fwb2017-03-14

I know the 80pc is a cheaper deal but the amount u spend on this project depend on directly how you source, may be you have ur items at home only.
2ndly here you can buy good bits that will last you long and can be job specific.
I Have a Dremel but this is better in some case, I am planning to use this an engraver and drill in my coming drill press .

gcai_fwb (author)geekrex2017-03-14

thnx for the input - I was just curious - not intended to negative

ToolboxGuy (author)gcai_fwb2017-03-15

This one is a great stepping stone for other projects. Thanks!

geekrex (author)gcai_fwb2017-03-14

No problem man , you are always welcome .

3366carlos (author)2017-03-14

Awesome, I just recycled my 18v drill, I wish I had kept the motor.

DejayRezme (author)2017-03-14

Awesome! I've actually been thinking about doing something like this myself. This would be great with rechargeable 3.7V 18650 vape batteries used in e-cigs.

But I think a rotary tool usually has a better balanced motor shaft and chuck and uses ball bearings to take sideways and frontal loads without wearing out the motor.

Antzy Carmasaic (author)2017-03-14

Nice drill. How did you connect the chuck to the motor shaft?

4DIYers (author)2017-03-14

Great work! Good to see old parts being repurposed, such a waste to throw good parts out.

skywayman (author)2017-03-14

Step 1: Spend $1,000 on a 3D printer. Step 2: Start this instructable.

geekrex (author)skywayman2017-03-14

Sorry but you can use any enclosure that you like PVC pipe it totally on ur creativity.
Btw the printer is 1/10th the price only 169$

MissNewtype (author)2017-03-14

You should use a potentiometer of some sort to adjust the speed.

geekrex (author)MissNewtype2017-03-14

Actually, I have a speed controller,previously made .

CorisaF (author)2017-03-14

Maybe it cost extra but, I don't know a kid that doesn't love to learn how to make something like this. And if you have a group of kids, boy/girl scouts or a family night (I have 6 boys), or a parent child activity, it not only gives everyone a fun new tool, it creates bonding and experience and teaching and learning and all that warm fuzzy stuff. Making a $5 radio was hella better than buying $1 clock radio's. And the faces light up when they did it. And a $5 project normally ran me at least $60. Multiply everything by 8. 6 kids and extra parts.

3366carlos (author)2017-03-14

nice, what DC adapter are you using to power it?

geekrex (author)3366carlos2017-03-14

I am using a 24 V 2.5 A adapter.But it consumes 1.5 A max

ankurvarma (author)2017-03-13

Can it be used to Cut metals ?

geekrex (author)ankurvarma2017-03-13

It can cut bolts and nails .

About This Instructable




Bio: So basically i am a crazy person, who loves to think the most odd way ever possible,who makes what he thinks and also let ... More »
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