In this Instructable we'll create a simple footswitch for turning on/off a mains powered tool (dremel/drill press/etc.).

Bill of materials:

You should take into account the power specs for the switch/cord and power tool (power of switch/cord > power of tool).

Tools:

Step 1: Body

The body is composed by two pieces of wood:

A hole should be cut into one of the boards to insert the switch.
On the second board, and below the hole on the first, use the router to create a small depression in the wood. This depression will be used to accommodate the wiring.

Use the router to cut a groove to allow the wiring to get out of the body. This groove should be cut in such a way that the cord is not loose inside it.
Drill some holes for the screws on the second board.

Step 2: Electrical Stuff

To save space and to keep the number of connections to a minimum do the following:

Peal off the outside insulation of the power cord somewhere in the middle (see youtube video).
Cut on of the wires in half (not the ground one).
Stick the two newly created ends into the switch.
Slide the outside insulation so that the remaining wires are not exposed.

Attach male and female plugs to both ends of the cord.