Introduction: Mini-Tablesaw / Router / Shaper for Dremel Rotary Tool

Mini - Table Saw / Router / Shaper
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.

Material Supply:
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

Attachments/Accessories/Tool List:
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
7/64”Drill Bit
1/4” Drill Bit
Phillips screw driver
Elmers glue
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

Step One - Cut the wood to proper length:

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.

1x8x4:
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)

1x2x4:
4 - 5-1/2” in length (braces and brackets)
2 - 12” in length (optional extension arms)

Step 4: Table Top and Back Panel

Step Two - Cutting / Drilling the 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

Step Three - 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

Step Four - 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

Step Five - 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

Step Six - Table Saw and Router/Shaper 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

Step Seven - Fence for Table Saw / 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

NOTE: This instructable only covers the original table.  There are additional instructions to add an extension and rulers to the table top. 

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!

Comments

author
Digthatwood made it! (author)2017-05-29

Cool project

author
Francisco196582 made it! (author)2017-05-14

Excelente projeto

author
OzgurL1 made it! (author)2017-03-06

did it. great project. thanks a lot

author
TammyLien made it! (author)2016-12-10

what if I don't have the mini saw attachment but want to use saw wheels?

author
clareville made it! (author)2016-06-12

I am confused by the board dimensions in material supply list. Converting to metric is not a problem, but in 1x8x4 which numeral is inch and which foot

author
seçkins made it! (author)2016-06-02

Tank you

author
JackieC29 made it! (author)2016-05-18

You sir, are a genius.

author
callhow made it! (author)2016-03-21

Awesome build. Is there a way to adjust for height of saw blade ? - callhow

author
BruyèreF made it! (author)2016-03-02

I am an European from Belgium and I am not so good with feet and inches. Could you tell me for example 1 x 8 x 4 are this feet? Because I have problems with the thickness of the board. How thick should the board be?

author
RaduB9 made it! (author)RaduB92016-03-12

1 inch thick 8inch wide and 4feet

in EU you go by 22mm 32 mm and 38mm

32 is 3/4inch 32 is 1 1/2inch 38 is 1 1/2inch

will be your choice what you will use

author
sumtonian made it! (author)2016-03-02

Very intelligent and inspiring project.

Thank you very much for publishing.

I made an easy one with dremel holder and acrylic board.

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author
stannickel made it! (author)2016-01-15

Inspired by this instructable, I made a simpler version to be used only for cutting perfboards and copper clad boards for electronic projects. I also made a small fence that I can use on the right or left side of the cutting wheel. Note that to make an expanded area on the left side, I made a hollow using a small drum sander to accommodate the Dremel contour a little bit. My Dremel is a very old M370 model. I did not worry about having a 90 degree angle for the cutoff wheel. I do wish I had made the table a little longer on the right side, but for the boards that I use, this table is adequate.

upsidedownhollow.jpgfenceonleft.jpgfenceonright.jpg
author
treymartin82 made it! (author)2015-09-01

What is the saw piece that you have on your Dremel? I have cutting wheels but not that piece. Thanks.

author
KrystianO1 made it! (author)2015-03-07

I'v made one :) really cool thing :) Had to work with what I had so the base needed a 2 inch extension. To accommodate the dremel when mounted veritacly. I've used a jigsaw to cut the pieces... horror. Ended up buying the router mount extension (good offer and with 3 bits included)- there is an instructable on making one yourself. It took me 3 days of when I could work on it, altogether, about 5 hours. With proper tools I can see it done in 1-1,5hr. Now That I have one, I think I might make another. Thank you for a fantastic and useful tool!!!

dremel table (1 of 3).jpgdremel table (2 of 3).jpgdremel table (3 of 3).jpg
author
mbadavid made it! (author)2015-02-15

another question - are the screws that hold the plastic to the top also holding the top to the base?

author
CagedChimp made it! (author)CagedChimp2015-02-22

Nope, if you look at the plans (or the images above, you'll see that there are some extra screws holding the wood together.

author
mbadavid made it! (author)2015-02-15

great instructable. Thank you,

I am in the middle of making it. One question though. Could you cut a slot in the top made for routing and just have one top? Or is there a function to having both tops as separate?

author
CagedChimp made it! (author)CagedChimp2015-02-22

You could have one top, but it is safer to have two, and you can cut smaller pieces with the saw, and use the router on smaller pieces as well. The top will stop pieces from falling into the saw or router. Think of it as a zero clearance insert for a normal table saw.

author
piper1234 made it! (author)2015-01-12

awesome with a lil of customizing fits for another dremel or even in no dremel similar rotary tools many thanks :D

author
piper1234 made it! (author)piper12342015-01-12

oh and even the pdf with all specifications ready to do very good one :D

author
Aythamie made it! (author)2015-01-01

Hi,

I finally got a Dremel 4000.
After seeing a video of your project online, I knew I had to make this.
However I see that it was released 4 years ago.
I suppose there have been many mods to it and maybe even a v2?
What are the best mods for this project?

Second, it's really hard in Europe (minus UK) to find wood in imperial size. Not that I've tried but I know I won't find anything.
Does anyone have the plans in metric. There was one comment made 4 years ago but the link isn't working anymore.

Thanks!

author
clusterflop made it! (author)2014-11-16

What the heck are "boarders"?

author
SpinnerDave made it! (author)2014-10-02

Neat design, I have a German Proxxon rotary tool, and drill stand.

Proxxon drill stand is well made, but limited in scope.

I'll try your design with modification for profile of different rotary tool.

Not sure where gargoyle169 is coming from, is he planning to rip lengths of 4x2, or build a kitchen?

Also a bit confused by his use of "widget". I was under the impression a widget was a Windows desktop executable file.

Keep up the good hobbyist designs, thanks.

author
pgupta31 made it! (author)2014-09-10

Hi,

Nice work. Plan to make one for me. If I keep the dremel in vertical position as you did for routing and use a 90 degree attachment and 50 mm hss blade and some modification on top ,can it be used for cutting higher depths

author
Jakonator made it! (author)2014-08-17

What's the total cost of this.

author
kymbrly made it! (author)2014-03-05

I made this saw about three week's ago and I love it. The plans were very easy to follow and the saw came together very nicely. It was a lot of fun as well. I don't use it for "real work" just small wood cut's and it is awesome. Thank's sdudley

author
gargoyle169 made it! (author)2014-03-01

When that offset angle cutter attachment first came out, I bought three. I am a manufacturing engineer. I wanted to see how much work I could get out of one of these.

Unless you own stock in Dremel, dont bother. The widget you are modifying here does NOT warrant the effort, They burn up after a few hours of real work.

Dremel is a hobbiest, home toy widget.

I solved my problem with a four inch diameter mini table saw from (rhymes with) Slobber Fright. Put some re machined bronze bearings in it and have gotten three years or prototype slicing, gee whiz making, wonder what it, building out of it.

author
mmiocevich made it! (author)2014-01-15

Fantastic article! I am definitely going to make one, but I am wondering whether anyone has the mock up for one in metric? Metric paper rulers would also be really handy as well. The link given before to a person who had put one together in metric no longer works, so I am searching for a new one. Any help?

author
mcsk8rg made it! (author)2013-08-30

HOW DO YOU MAKE SURE THE ROTARY TOOL IS EXACTLY VERTICAL ?
WHAT IF ITS NOT ? THATS A BLUNDER THEN....
AND
DON U FEEL THE NEED TO SLIDE YOUR ROTARY TOOL UP N DOWN ACCORDING TO SITUATION REQUIREMENT ?

author
sdudley made it! (author)sdudley2013-09-01

In the vertical position it does quite nicely. Mine holds very well. Yes, it moves up and down very easily and has quite a bit of range in height. Is it exactly vertical? Well, I never bothered to square it up, but then again it is only for hobby use and crafting with soft woods and plexiglass that do not require precision cuts and accuracy. If I need precision, I do not use a Dremel.

author
mfkeough made it! (author)2013-08-10

Wow! Great Instructable - the printable TDP is icing on the cake.

author
vicvelcro made it! (author)2013-06-05

I've made two of these. One was a gift and one for myself. I didn't plan ahead on my own unit, my dremel is cordless and the battery makes it too long in the vertical axis when using the router bits and sanding drums. Aside from my own lack of foresight, this thing is fantastic for small work.

Thanks for this one, sdudley.

author
sdudley made it! (author)sdudley2013-06-05

Glad you enjoyed it. Dremel has made so many different rotory tools over the years, it would be a little time consuming to draw templates for each one. When I made the prototype, I simply layed the tool down and traced around it. That's what gave me the idea to create the template. I guess I should have mentioned that in the instructable.

sdudley

author
vicvelcro made it! (author)vicvelcro2013-06-06

I think your contribution was just fine. I don't see how you could be expected to account for all previous, current, or future models of the tool.

The failure to analyze and think ahead was purely mine. I was in such a hurry to get mine completed and begin using it, I just didn't take the time to account for the added battery length for my unit. Easy to fix, when I get around to it. A lengthy unit isn't really anything to complain about...

All in all, it's been quite beneficial. I hope my original comment will help others not make MY mistake.

author
journeyman77 made it! (author)2013-01-03

Hi, great project and i am about to start building it.
I saw your response for metric system dimensions. I want to make the whole project a bit bigger eg 1,5x times the original. What dimensions do i have to change?
Another question is what about using it as a router, how we change the height of the dremel tool while in vertical position?

author
SolarPoweredGardener made it! (author)2012-11-29

Thank you for this design. I built it about a year ago and it's worked great. I did manage burn out the saw attachment though. I use it mainly for model making, ripping balsa sheets. I tried some MDF that was a little much for it and the saw attachment fell apart. I bought a new one and will be more carefull...

With my acyllic top I only get about 3mm cutting depth. I can rip 5mm balsa with two passes. I was going to try 1mm carbon fibre sheet but it is a bit pricey. What I did was found a 40mm blade on ebay. With a bit of DIY I managed to fit it in the saw attachment. I had to remove the spring loaded safety cover to make it fit. I can now cut around 6 - 7mm. Remembering to take it easy....

author
sdudley made it! (author)sdudley2012-11-29

I am glad your enjoying the saw. I use mine quite often to cut 1/4" acylic sheets that are actually 0.22" thick. It barely clears the top of the sheet and if I try to cut something that is 0.24" thick, I need to make a second pass by flipping the piece over.

I had planned to redesign it using the flex shaft and some larger saw blades I found at Harbor Freight Tools: http://www.harborfreight.com/catalogsearch/result?q=rotory+tool+saw+blades

This would omit the need for the saw attachment and give me a little more hieght from the blade. However, I am designing several other tools which use the Dremel as the power source, one of which will be a new table saw, but I have a long way to go before I finish everything.

author
hovnosmakom made it! (author)2012-10-12

Everything went smooth, up to the part with the acrylic top. I don't have a countersink drill bit and the screws always stick from the acrylic, making me furious. Do you have any ideas as to how to do it properly without the countersink bits?

author
sdudley made it! (author)sdudley2012-10-12

You will need to countersink the holes in order to get them flat with the surface of the top. I don't have a countersink bit either, but what I do is use a larger drill bit that is about the size of the screw head. If you try this, be VERY careful not to drill all the way through and make the hole too large for the screw. You will definitely want some type of drill press with a stop on it to prevent you from drilling too far.

One thing I want to do, is get rid of the acrylic top and use a thin piece of aluminum or stainless steel sheet instead. I have not done so yet, but I think it would work much better. You just need the proper tools to work with that type of material which I don't have.

Stacy

author
Bradinsc made it! (author)2012-09-23

Just finished making two of these mini saws. They work very well, I was really pleased with the plans! Made making the tables a real breeze. I did a few small modifications, I made the tops out of Lexan, and added the same on the extension tables. I also mounted the extension table permanently to the extension arms, so all I need to do is remove the bolts on the table and swing the extension around to use it on the other side, eliminating the need for clamping it down, works well! Added a pic of them, one matches my Model RR setup, the other matches my dads, he will be getting this a new Dremel 4000 for Christmas! Thanks so much for the plans! I really enjoyed building them.

Mini Tables Saws complete.jpg
author
sdudley made it! (author)sdudley2012-09-24

Awesome! It's always nice to see modifications people add or change to make projects better. I like the way you made the swing arm for the extension table.

I am currently in the process of designing a modular bench for all my Dremel tools and accessories. It is a 2'x2' cube that expands to 6' long x 2' deep with an interchangeable center work area. I plan to use it as a tablesaw, router, drill press (using the Dremel work station), small manual milling machine, and a few other things that come to mind.

I am drawing it up in Google Sketchup, and started putting together the basic structure this past weekend. I still have a LONG way to go and many modifications before I think about making it an Instructable though!

If you have any suggestions, I am open to any thoughts.

Stacy

author
nduetime made it! (author)2012-06-10

Great job!
Any thoughts about making a drill press/router table unit?

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Bradinsc made it! (author)Bradinsc2012-08-06

I do have the Dremel brand Work Station, I think that is what you are talking about. It works as a drill press and also holds the Dremel horizontally as well for sanding. It does a great job! Has a hook to hold the Dremel by the bale to use the flex wand as well. I clamp mine down with toggle clamps and use it quite a bit. I have a big floor model drill press, but its too much machine for small jobs. I got mine on Amazon for about $40 I think.

author
sdudley made it! (author)sdudley2012-08-06

Yes that is something I have thought about quite often but I already own a separate table top drill press so it's low on the list of projects.

Stacy

author
Bradinsc made it! (author)2012-08-05

I got (2) Dremel 4000s from Amazon, and went to Lowes the other day and got all the parts to build two of these along with the extension tables. One is for me and one is for my dad for Christmas. We both do model RRing and I think this will be a great tool for working on the buildings etc. Thanks for the plans! I will post when I am done. Also another tip, When I was shopping my list at Lowes, I found for a few $ more I could get pre-cut 8x10 sheets of Lexan for the tops. Pretty much bullet proof and worth the extra $ for the wear and tear I am sure the top will sustain! It was about $3.50 per piece. Worth it in my book.

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sdudley made it! (author)sdudley2012-08-06

Sounds great! I was also thinking of using an aluminum plate instead of plexiglass or Lexan, but haven't bothered taking the time to do it.

Enjoy!

Stacy

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Bradinsc made it! (author)Bradinsc2012-08-06

I will let you know how it works! Thought I would be able to see the rulers through the Lexan. :) Thanks for the plans!

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WroblewskiWrocketry made it! (author)2012-05-13

Has anyone used the dremel brand router table, #231? Is it a sturdy piece?

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jeditanker72 made it! (author)2012-04-29

Truly awesome design. Thanks for giving me some inspiration to get back into the garage and make something.

author
dmanmoka made it! (author)2012-01-31

Really good plans and design! love it.
I will post pictures along the way :)

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