NOTE: This is a very dangerous instrument and i am not responsible for any way you decide to use it. or any injuries that may take place. On average, 1 finger is amputated by a Table Saw every 9 minutes, i too have had my run in wit h this saw, but my reflexes kicked in and it only left a scratch, Just warning you.
Materials you will need:
- 3 or 4 2x4x12 (12 Foot two by fours)
- 1 electric circular saw like the one in image #2
- 1 Piece of Plywood, at least 2' x 6'
- 1 Red-Capped Toggle Switch with either 2 or 4 connectors on the back
- An Old Extension Cord or ZPMRelay" and 2-Wire Cord
- 3 to 4 carriage Bolts with washers and nuts
- About 20 2x4 Nails or Screws
- About 32 Plywood Nails
- 2 - 3 Wire Splices
Tools you will need:
- Various Metal and Wood Drill Bits
- Hammer or Nail Gun
- Wire Strippers
- Wire Cutters
- Wrench to Match the nuts for the carriage bolts
- Socket Set
- Tape Measure
- Chalk Line
- Saw, preferable electric.
- Compass Saw, Keyhole Saw, or Saber Saw
- Hot Glue Gun (Recommended, but not needed)
Step 1: Step 1: Cutting the Boards
- Gather at least 3 2x4s and cut 1 in half, 1 in 3rds, and 2 4-foot pieces out of the other.
- Cut ONLY ONE 4 foot piece in half.
- Next use your tape measure and go along the longest side of your plywood, measure 6 feet, then mark it, do the same to the parallel side.
- Then run the chalkline between the two points that are parallel,
- Then, on the short side you started at on the first one, measure out 2 feet, then make a mark.
- Then, on the line you previously made with the chalk line, measure 2 feet parallel to the other 2 feet and make a mark.
- Snap the chalk line between the two marks.
- Then run the Circular saw, that ironically will be attached to it later on, and cut along them chalk lines. You could attempt to use a handsaw if you have nothing else to do.
The plywood should be a perfect rectangle now and ready to be 'carved' in the next step.
Step 2: Step 2- Forming the Top of the Table
Measure 1/2 of its width, make a mark, measure 1/2 of its length, make a mark, Wherever they intersect, make another mark. (Image 1)
Make a plunge cut directly on the mark in the middle parallel to the 2 foot sides, carefully move it up about 1/4 a centimeter and then back to the center, then down about 1/4 a centimeter, this should give it room to circulate when it is spinning in the 'crack'. (Image 2)
There should now be a long rectangle in that location, measure out 1/4" from each Corner to the 2 foot sides (after here, refered to as sides) and make a mark, then drill it with a 1/2 drill bit, to fit the saber saw into. Then use the saber saw to connect the drilled holes, use precision so it won't be crooked, you want it to be as strait as humanely possible. (Image 3 and 4)
Then measure 1'6" (1 Foot, 6 Inches) from the left side, then up 2 inches, drill a hole with a 1/2 drill bit. (Image 5)
Now, using that hole as a sawpoint, cut out a square, the size of the switch with the saber saw. BE SURE THERE IS AT LEAST AN INCHand 3/4 OF WOOD BELOW IT so it doesn't break off and so u can fit it on the base. Then Fit the Switch in there using Hot Glue or brackets if needed.
Step 3: Step 3 - Build the Table Base
- Take all of the 6 footers and one of the 2 footers and nail them togather in the corners to form a rectangle. I'll let you decide how to do it, perhaps make a miter cut on the ends. (Image 1)
- Take the legs, and nail them to the inside. (Image 2)
- next nail the piece of plywood to the top
Step 4: Step 4: Configuring the Circular Saw
IMPORTANT: DO NOT DISASSEMBLE THE MOTOR HOUSING OR GUIDES.
Take the handle off, take off the switch, connect the wires together (depending on the model), this only works if there is 2 wires for the switch, if not, send me an email @ email@example.com with a picture of the switch and i will try to interpret the correct wiring patterns. Then u can reassemble the handle. and test it out by plugging it in, but take the blade off first so it don't kick back. once u confirmed that it works, cut the plug off the cord and wire one of them to the switch .
Now u need the old extension cord, cut the female end off of it then strip the wire, then the wires inside of it, hook one end into the switch, then splice the other remaining 2 wires togather.
then drill 4 holes around the parameter of the base, as in image 1 then align the blade in the middle from under the 'table' and drill holes in the same location you can turn it upside down if it helps,. Then send the carriage bolts through the top of the table into the hole amd then put a washer on it and bolt it half way, then put the rest of the bolts in the same way and tighten them down to an estimate torque of 100 Newton Meters then plug it in and see if it works, if so, then you just made your own table saw, if not, sent me an email, which is listed above with a description of your problem and a picture of the underside of the table.
Thank you for taking time to review and/or attempt my tutorial, sorry if things didnt' work.i will help as much as i can.