Metal Cutting Saw From Wood

This is my entry for the Huricane Laser Contest.  I want the Huricane Laser so that I can make AWESOME simple kids airplanes that are modeled after real planes, like the A-10 Warthog!  (like these: http://www.hobbywhatnot.com/187_page_1107619.htm)

This saw can be built in a single evening, and if you have to buy EVERYTHING will cost around $80.  My total cost was $28 for the sheet of plywood.  Everything else I had on hand.  I've used it to cut through 1.5" Aluminum Bar Stock, 1/4" 2x3 angle, and 1/8 2" Pipe.  It will pretty much cut anything eventually.  And it's automatic, just start the cut, and keep an eye on it to stop it when finished.

Tools You Need:
1. Wood Saw (I used a miter saw, and a table saw, but you could do the whole thing with just a hand saw.
2. Drill Press (You could make this without it, but it is WAY WAY easier to be precise with one).
3. Carpenter's Square
3. Basic Hand Tools

Materials you need:
1. A Reciprocating Saw.  If you sign up for their coupons, you can get this one: http://www.harborfreight.com/6-amp-reciprocating-saw-with-rotating-handle-65570.html for $20.  This one is what I used and is perfect because it's easy to mount once you take off the handle.
2. Some Plywood (3/4" although 1/2" will work).
3. A light dimmer switch (optional).
4. A wood working vice like this: http://store.cbtoolgroup.com/jorgensen-woodworking-vise--4-12-p4302.aspx?utm_medium=cse&utm_source=googlebase  I used an 8" vice I had.
5. Some 1/4" 2" bolts with nuts and washers for attaching the vice.
6. 4' or so of 2x4.
8. Some zip ties.
9. Some heavy stuff for weight (I used an old motorcycle starter, and an adjustable pulley).
10. Some High Quality Large Hose Clamps (6" or more).
11. One 8" Or Longer 5/8" Bolt (with only the end threaded) or a 5/8" rod / shaft. (A 5/8" hardwood dowel will work too)..

Step 1: Remove "Extras" From Reciprocating Saw.

Most reciprocating saws have a lot of extra plastic and stuff that isn't structurally important.  To make the finished product more compact, you can trim all this off.  If you buy the harbor freight saw I recommend once you take the handle portion off, you are left with a nice compact little saw that is easy to mount.

Comments

[Topcat2021]

That's a great idea, I may have to build one of these for myself, as it is a whole lot easier than building a powered hacksaw (which I may still do),
Keep up the good work
Dan

[joeynovak]

Thanks Dan,

Totally why I did it... Way way easier then a power hacksaw.

If you do build a power hacksaw, make an instructable :) I'd love to see it.

[pfred2]

I have this:

http://i.imgur.com/YvLQO.jpg

It works pretty good:

http://i.imgur.com/QsCXj.jpg

I just don't use motor oil as cutting fluid with it.

[Lectric Wizard]

This is a great idea & I'm looking around for a cheap used reciprocating saw to make one. I too will join the ranks of the ignorant & use motor oil,haw,haw,haw !!!!! THANKS!

[joeynovak]

lol... Awesome!

[pfred2]

I have aluminum cutting fluid. You can cut aluminum with a carbide circular saw though. When cutting steel whatever is not the right answer. Some oils can actually interfere with the cutting process. Oil is designed to reduce wear and tear so it being a poor choice as a cutting fluid should be obvious. If you do not have proper cutting fluid you should stick with plain water. Once you are done with your cut you can drive any remaining water off with whatever. Well, not motor oil, because motor oil is a moisture trapping desiccant. Not a good material property for a substance that will remain in contact with other materials that could oxidize. The reason motor oils are made how they're made and work how they do, is because of the specialized environment they are engineered to work in. Engine crank cases.

Using engine motor oil outside of its specialized application is just ignorant.

Sharing is caring so I figured I would :)

[Lectric Wizard]

So we should use WATER instead of Motor oil because motor oil might contain WATER ????

[pfred2]

Motor oil traps water and is a poor cutting fluid. Which is a good thing because you wouldn't want your crankshaft to cut through your main bearings now would you? You should use plain water because it has better cutting properties than engine oil. Water cools well too. Just remember to clean the water off your tools when you're done. Water cleans up remarkably well. Dirty foul engine oil doesn't.

[general-Insano]

The motor oil traps and keeps water from rapidly dissipating whereas you can quickly remove water without difficulty.

[Lectric Wizard]

You can also remove motor oil quickly ...

[joeynovak]

Our of practical reasons, I use Motor Oil. While water based cutting fluids may be Superior (idk). I've always used motor oil with no ill effects. My biggest concern is my equipment. Oil won't cause them to rust.

I don't do a lot of machining either. I've had the same quart of motor oil for over a year, and I've only used about a 1/4 cup or so. It's amazing how little oil it takes to make a HUGE difference.

Although, I may get some water based cutting fluid to try and see if it allows me to run faster speeds without burning up drill bits and blades, but I suspect it doesn't make THAT much difference.

So, I wouldn't say it's ignorance, rather just what works.

[general-Insano]

lol i had the exact same idea a month ago, I just never got around to implement it though :D

[rimar2000]

Useful tool, thanks for sharing your idea.