Combination Circular/Table Saw

I needed a table saw to make a frame for a Fresnel lens, and I was asking some of my fellow grad students if they had a table saw I could use. I got a couple of hints where to find one on campus (which I eventually did), but a friend of mine made a particularly interesting observation.

"Yeah, it's strange that they don't make a circular saw that just snaps into a table so you can use it as a table saw."

And thus the seed was planted. I remember at the time I brushed it off, but a few days later a friend and I decided to sketch the plans out for one and try to make one with three criteria:

1) Make it cheap.
2) Design it so that all you need to build it is a drill and a circular saw.
3) Design it so that you can easily remove the circular saw when needed.

The video below is a time-lapse of us building our Circular/Table Saw over the course of ~4.5 hours. We were planning as we built, so I am confident that this could easily be replicated in 2-3 hours.

Step 1 Materials

Required Tools:
Circular Saw (More on this ahead)
Drill

Optional Tools:
File
Chop Saw

Hardware:
1/4" 20 Machine Screws
1/4" 20 Wingnuts
1/4" Lock Washers
2" Wood Screws
3" Wood Screws
Zip Ties

Lumber:
3 2x4's (Pine)
2 1/2x1's (Pine)
2' by 4' sheet of particle board

Everyone has their own method of selecting lumber, we like to look down the length of the wood and search for warping. Sometimes I like to lay the wood on the ground and see if it rocks or falls over, but this method requires the floor is even. Finally, make sure there aren't too many knots.

All in all, this project should cost less than $70. That's including the cost of the circular saw and all components (but assumes you own a drill and the necessary drill bits).

Comments

[tetraflak]

This instuctable is on my todo list. You guys did a great job!

[pilotneko]

Hi guys, I got a few messages that my time-lapse video was difficult to watch. I sped it up and added a soundtrack (terrible music, I know!). I don't want to affect my chances in the Craftsman tool contest, so I'll just post it here in the comments:

[rimar2000]

VOTED!

I maked years ago a cutting table like this, and it have been very helpful. I still use it on a regular basis.

[Xuster]

Hey guys,
Just to let you know that what you are showing up here is extremely dangerous. You really need to use a miter gauge when crosscutting on a table saw NEVER a fixed fence as we see in the photo. If the angle of you wood piece had changed for any reason while you were riding against that fixed fence the blade would have catched it and throw it across the room or worst in your face. I learned this the hardway and received a piece right above my family jewels (ouch!).

here is a video where a pro makes the same statement.

http://www.ehow.com/video_4427310_cross-cut-table-saw.html

be safe and enjoy you new toy!

[jdege]

This is less dangerous with a table-mounted circ saw than with a real table saw for the simple reason that the circ saw motor doesn't have anything like the same power.

A circ saw is more likely to stall than to throw a piece of any size.

[neffk]

It's not magic---it's just a matter of keeping the piece from twisting. When the short edge is against the fence, it's harder to keep straight.

[Phil B]

I did something like this many years ago, but wanted to be able to use a miter gauge.  I also wanted to be able to remove the saw to rip panels, etc.; and then return it to the saw table quickly so that it is in the same precise alignment it had when I removed it.  I also wanted to make precise rip cuts.  My Instructable appears in the related Instructables above, or you can view it here.  It was very little effort than what you did, but should give you some additional useful features.

[pilotneko]

Your instructable is really very nice, I like the miter gauge you added. I'm not sure if I was too clear in the instructions, but the circular is removable on our setup as well. Much like you said, I was interested in keeping the saw functional as a circular saw. It only takes a minute or two to remove the saw from the table or reattach it.

[Phil B]

The important thing is that our projects work for the purpose each of us has in mind to fit our needs. And, a couple of times I have modified something after I posted it. What we post is not necessarily the final word. It is handy to be able to remove the circular saw and use it for other purposes. Thanks for publishing your Instructable.

[neffk]

I did a similar project, last year. You have much nicer pictures, though.

http://www.instructables.com/id/Convert-a-hand-held-circular-saw-into-a-table-saw/

[pilotneko]

Nice! I'm sorry I missed your project the first time around. I usually lurk around Make:Blog and am just starting to get into instructables.

How's the table saw holding up?

[neffk]

I used it a lot for several months. I ended up finding a good used Delta for 100 $, which was a good deal. If I hadn't found a cheap saw, I would have continued to use my DIY saw.

[jdege]

I've been thinking about making an insert for my circ saw that fits into my router table top. That'd let me take advantage of its fence and miter slot. I might make another for my jig saw. And maybe for a Dremel, so I can use it as a small drum sander.

[pilotneko]

I think that's a great idea! I've talked to my father about doing this, and he actually suggested I modify a router table to be able to do both. In the end, I just decided to make a simple table saw that could be built with nothing but a circular saw and a drill.