for Dremel rotary tool.
Now that the Dremel contest voting is over I guess it's ok to update this instructable. Here is a "supplement" video showing the table saw extension in action. :)
Step 1: Get Templates Here!
I am attaching a PDF that includes the templates I made for this project. Open the PDF and save it to your computer.
Print out the templates (I suggest using 100 pound card stock for the templates).
MAKE SURE... that you select None in the Page Scaling option when printing!
If you fail to do this the printer will scale the pages to a different size and the templates will not be correct.
Step 2: Material Supply
You will need a Dremel rotary tool (obviously)...
I purchased the 4000-5/36H from Home Depot which has 5 attachments and 36 accessories for $99.00! This is by far one of the best deals available for the Dremel products. I highly reccomend it.
1 - 1x8x4 (I used top choice whitewood board)
1 - 1x2x4 (I used top choice whitewood board)
2 - Optix 8x10 acrylic sheet (.080” thick)
1 bag - 3/4” two hole pipe strap - (sold in bags of 4)
2 - 1/4”x 4-1/2” bolts
1 bag - 1/4” wing nuts - (sold in bags of 4)
1 section - 3/4” foam pipe insulation (sold in 6ft sections)
2 bags - Wood screw - #6 x 1-1/2” - (sold in bags of 10)
1 bag - Wood screw - #4 x 5/8” - (sold in bags of 12)
2 - 2” Spring Clamp
Dremel Rotary Tool (templates were designed for model 4000 but can be modified to fit any model)
Dremel - Mini Saw Attachment (model 670)
Dremel - Sanding Drum (either model 407 or 470 will work for this application)
5/32” Drill Bit
5/64” Drill Bit
1/4” Drill Bit
Phillips screw driver
Utility knife (or other razor)
Optional Dremel Attachments/Accessories:
(only needed if you plan to build this project *exclusively with a Dremel Rotary Tool)
Dremel - Plunge Router Attachment (model 335-01) “OR” Multi Purpose Cutting Kit (model 565)
Dremel - Circle Cutter and Straight Edge Guide (model 678-01)
Dremel - Brad Point Drill Bit Set (model 631-01)
*Note: the top plate cover screws require a tapered 1/4” counter sink. The Dremel Brad Bits are not tapered and Dremel does not currently make a tapered 1/4” drill bit with a 1/8” shank. This will require the need for an additional drill (preferably drill press) that can handle standard 1/4” drill bits or 1/4” tapered counter sink bits.
Step 3: Cut the Wood
I suggest when purchasing the supplies, have the hardware store cut the wood for you. This will save time and assure clean straight cuts. The following are the cuts you will need to make this table.
2 - 10” in length (table top and back plate)
2 - 4” in length (left and right side panels)
1 - 8” in length (optional table extension)
4 - 5-1/2” in length (braces and brackets)
2 - 12” in length (optional extension arms)
Step 4: Table Top and Back Panel
Once you have all the wood cut to length, print out the templates and look through them. For best results print the templates on 100 pound card stock.
Starting with the Table Top template you will notice a bold boarder, several faded dashed lines, some drill hole placements and a bold dashed line that represents the cutout for the Dremel rotary tool and Mini Saw Attachment.
There is also a faded solid line that represents the pipe strap that will be mounted underneath the Mini Saw Attachment between it’s directional guide and coupling (see Mini Saw Attachment operating instructions). The faded lines in each template represent items on the opposite side of the viewing perspective (as if the template were transparent). Cut the template along the boarder and also cut along the dashed line for the Dremel and Mini Saw Attachment.
Select one of the 10” panels (cut from the 1x8x4) to be your table top and lay the template over it. Secure it with some scotch tape or simply hold it in place while tracing the outline of the Dremel and Mini Saw Attachment (1). Use a punch, nail, or screw to mark the drill holes. Put an indentation into the wood to help steady the drill bit when you start to drill the holes.
Clamp the panel down and route out the area you traced using a Dremel Plunge Router or Dremel Multi Purpose Cutting Kit (follow the instructions for those tools using appropriate routing techniques) (2).
If you do not own one of these attachments, then use a jig saw or other means of cutting the wood. The template was designed so the Dremel tool and Mini Saw accessory will fit snug, so continue working the edges until they are just able to slide through the top plate.
Once you are finished routing, drill the holes using the appropriate bits (labeled on the template). Note that if you are planning to build this project using only Dremel tools and accessories you will need the Dremel Brad Point Drill Bit Set for the 5/32” and 1/4” drill holes / counter sinks.
Here’s a tip - if you don’t have access to a drill press to counter sink the holes, use the 1/4” drill bit to first drill into the wood just enough for the counter sink. Then finish drilling the hole using the smaller drill bit.
Follow the above instructions for the Back Panel. No routing or cutting is necessary - only drilling.
Step 5: Side Panels
The side panels are already the size we need for this project. However, you will notice on the template there is an optional decorative cut line. Feel free to use this if you would like to dress up your project a bit. On the bottom of the side panel page you will find what I call a “contour template”. This is for the left side panel only. The right side will need no additional cutting or shaping.
Cut out around the boarder and along the cut line. Fold along the lines and place the folded template directly over the top of the LEFT side panel (3). Make sure the side of the template labeled “outside” is on the side you want to be seen (one side of the wood usually looks nicer than the other). Trace the outline and use the Dremel to shape the wood until the contour matches “close” to that of the line. DO NOT sand this down too much at this time! For now just get close to the outline and later you can make for a perfect fit.
This contour will brace the body of the Dremel Rotary tool and help hold it in place. If you own a Dremel or rotary tool other than the model 4000, you will need to shape this area to fit the contour of your Dremel model. For the whitewood board used in this project a sanding drum will suffice when shaping the contour (4). If you wish to use a harder wood, you may need to use a different dremel accessory for this step.
Step 6: Brackets and Braces
There are two brackets and two braces (for use with rotary tool in vertical position). The two brackets will clamp the tool in place while the top and bottom braces will simply keep the tool from moving as you apply pressure when routing / shaping a work piece (5).
Follow the same procedure for these four pieces as you did when shaping the rotary tool contour for the left side panel. When drilling the 1/4” holes for the brackets, make sure they align nicely with the 1/4” holes you drilled in the back panel (6). You may even want to set them in place and mark them using the holes in the back panel.
Remember the rule - measure twice, cut once (in this case drill). It is recommended to use a drill press for this procedure. If you do not have access to a drill press, start by using a small drill bit first making sure to get good alignment, then increase the hole in steps until you reach 1/4”.
Step 7: Assembly
Once all of the pieces are cut, drilled, and shaped, it’s time to put it together.
Using the #6 x 1-1/2” screws, screw the side panels, top brace and bottom brace to the back panel. It is a good idea to drill pilot holes to keep from splitting the wood (the 5/64” drill bit should work nicely for this) (7). Before you can set the Table Top in place you will need to attach the 3/4” pipe strap to the bottom of the Table Top using two #4 x 5/8” screws. The 5/64” holes have been previously drilled so the center of the strap should line up very nicely over the cut out for the Dremel Mini Saw Attachment (8).
When you turn the Table Top over and try to set it in place, you should notice the strap will not allow the top to sit level. The edge of the strap overlaps the back panel. The easiest solution for this is to use a sanding drum to groove out a place on the back panel for the edge of the strap to sit into (9). Now screw the table top in place and assembly is complete.
Note that if you try and set the Dremel rotary tool and Mini Saw Attachment in place, the Mini Saw Attachment will not sit level with the Table Top (10). Cut a 2-1/4” section of foam pipe insulation. Squeeze it together then bend it so it is shaped as if it is smiling at you (11a). Place it into the cavity of the Mini Table Saw attachment turning it so the folded side is down (11b). Now when you place the Dremel rotary tool and Mini Saw Attachment
in place you should have to push it down to hold it level with the Table Top.
Now go back and finish the left side panel contour for your rotary tool. Set the Dremel rotary tool and Mini Saw Attachment in place (the on/off switch should be facing the front of the table saw and facing slightly downward).
Hold the tool in place making sure the Mini Saw Attachment is level with the table and look to see how high the rotary tool sits above the table. Using a sanding drum, sand down a little of the side panel contour and check it again. Continue shaping and contouring the side panel until the rotary tool sits just below the surface (12). You will need to repeat this process for the brackets and braces so the rotary tool is centered when in the vertical position. Remove just enough of the contoured areas of the brackets and braces to glue in place some foam insulation where the Dremel rotary tool will sit.
Step 8: Acrylic Cover Plates
When configured as a mini table saw, the cover is used to hold the rotary tool and Mini Saw Attachment in place. The acrylic sheets are 8”x10” so they will need to be trimmed down to fit the table top.
To do this, simply measure and mark a line at 8 inches and score the acrylic with a utility knife (run the utility knife along a straight edge or ruler) (13). Move the acrylic to the edge of a table or board and snap it off (14).
Once the acrylic sheets are the correct size, follow the templates to make the covers for the Table Saw and Router / Shaper respectively.
Step 9: Fence for Tablesaw / Router
To make the fence simply follow the same instructions for the Brackets and Braces. One side of the fence can be used when configured as a router, and the other side can be used when configured as a table saw.
Step 10: Optional - Table Extender and Rulers
You will need to download the original PDF on the intro page for the templates and full instructions.
I hope this will give some inspiration for creating some great Dremel craft and hobby projects!