Introduction: Dremel Saw Bit From Commercial Button

Picture of Dremel Saw Bit From Commercial Button

remember those commercial buttons you usually get at ellections and have nothing to do with afterwards ?! ever wanted to cut a piece of wood or plastic but didn't have the right dremel bit in stock ?! well, what are you waiting for ? start making them !

during the whole project it is VERY recommended that you wear safety goggles !

this dremel bit is NOT a HSS ( High Speed Steel ) tool - do NOT use this bit at high speeds !

this saw bit is effective on relatively soft materials such as wood, plastic, etc.

use this information at your own risk (there shuoldn't be any if you wear protective gear and use the bit with caution).

Step 1: Materials

Picture of Materials

the materials needed for making of this project are :

1. dremel
2. mandrel
3. grinding bit
4. grinding stone
5. drill bit ~2mm
6. commercial button
7. safety goggles

Step 2: Getting Started

Picture of Getting Started

take the button

notice it's made of 3 parts
1. bottom (attached to the safety pin)
2. top (the part we will be using)
3. top cover (the actual comercial - the printed part)

step 1 :
seperate the top with the cover from the bottom using a flat screw driver, knife or any relatively sharf and flat item

step 2 :
seperate the top from the cover (no tools needed)

step 3 :
RECYCLE the paper or plastic cover and the tin bottom

Step 3: Preparing the Shape

Picture of Preparing the Shape

as you probably noticed, the top part is not flat, it has a folded edge. what we want is a flat plate, to make it so thake the drinding bit and grind the edge - all the way.

what you will end up with is a circular 2D plate - like a thin coin.

Step 4: Making Sure

Picture of Making Sure

find and mark the middle of the plate and drill a ~2mm hole in that spot.

to make sure the plate is perfectly round and centered - put the plate on a mandrel and attach it to the dremel.

after doing so turn the dremel on and hold the grinding stone at the edge of the plate and apply miner pressure, by doing do we grid the plate so it is perfectly centered and round.

after centering and ruonding you can sharpen the plate by holding the grinding stone with a slight angle.

Step 5: Teeth

Picture of Teeth

to make the teeth of the saw take the grinding bit and just start grinding untill you get the shape of teeth you desire. make sure all teeth are identicle and not too deep - it will weaken them.
you dont have to make the teeth super sharp, remember, the saw itself is rather thin and spinning at 1000s of RPM !


thedude000121 (author)2010-11-20

thank you so much! finally! something i can cut wood with!


Isaac Laserman (author)2012-06-20

does anyone here have a purple cat I can test it on

ReCreate (author)2008-12-29

i want a dremel so baldly...I remember i used to have a dremel but we did not have the battery charger,so we threw it away

1thadeaus1 (author)ReCreate2009-02-18

i love my dremel! get a corded one...i have a corded one and i would rather not have a cordless one...i have a corded drill too...i dont regret it...

I know what you mean. My corded drill got stolen and now all I have is a cordless that won't turn.

IMO corded drills have more torque then battery run ones

geoslim13 (author)ReCreate2010-01-24

should have salvaged the motor

ReCreate (author)geoslim132010-01-25

 i think it was bad 

harari (author)ReCreate2009-01-14

well.. they don't cost much... just buy one - it's really useful (just remember to buy DREMEL and NOT SKIL - mine's a bit off centered, a lot bigger and less comfortable)

sensoryhouse (author)harari2009-04-10

I have 2 corded Dremels and I just bought a cordless one last night at Walmart for $20. Yay!

acardboardllama (author)2011-01-01

My dremel is my baby, this is a good idea but you could more easily buy a bit for it that will come with another bit attacher thing, and it will be much safer and perfectly round so you don't break it and die

nodnodwinkwink (author)2010-10-21

Any ideas on how to make the teeth as small as the original saws you can get?

coco911231 (author)2009-04-13

wow just the top of a button could turn a comment board into confessional cam wow...

klee27x (author)2009-04-10

Just a suggestion: Slightly bend each tooth up/down in alternating fashion. (Make sure you have an even number of teeth.) If you look at a real sawblade, you'll see this is the case. Either the teeth have inserts so that they are wider than the body, or they are bent outwards, slightly. The idea is that a saw cuts a channel that is slightly wider than the saw blade, itself. This reduces unproductive friction/heat that could ruin the saw and/or the material being cut.

kitmango (author)2008-10-24

I like your dremel bit, but does it work on other materials too? because, when plyxy glass is cut, it splits, like bamboo and it splits deep so please upload an other picture when sawing in wood or pvc plzplz ps sorry for my bad english, i'm not from an english country...

harari (author)kitmango2008-10-28

umm... I didn't really try in on different materials, I don't use it too often - I'll do some experiment for you and post them... I guess if you make it from stronger, less flexible and harder material it would cut through more materials. and hey, I'm not from an English speaking country as well (as you can tell from my avatar) where are you from?

kitmango (author)harari2008-10-29

I'm from the Netherlands,

harari (author)kitmango2008-11-04

cool, sorry I didn't post the videos yet, I'm in the Israeli army right now so I don't have a lot of time on my hands and I don't really have a variety of materials just laying around waiting to be destroyed. I hope I'll find some time and materials soon.

crickle321 (author)2007-12-18

Your idea is pretty clever. Do you know the translation of the Hebrew?

Switz (author)crickle3212007-12-19

I believe, if I can read it correctly, it says Ad Bo. Which means come forever or come for eternity, but I may be reading it incorrectly, cant tell if it is a Nun, or Vav.

harari (author)Switz2008-01-10

it says "AD KAN!" which means 'stop!' or 'up to here' and the fine print says "tzofim neged alimut" which means 'scouts against violence'

Switz (author)harari2008-01-10

Ok, I see it know. Where do you live? I have a friend in tzofim somewhere in Jerusalem. It wasnt easy to read xD. Shalom, Zeh tov me'od. Ani rotzeh lensot ha-tutorial shelcha. I fail.

harari (author)Switz2008-05-01

I live in ramat gan - about an hour drive from jerusalem, how do know hebrew? from him? sorry for the delayed response, I'm not at home too often because i'm in the army now, and when i'm home instructables is not at the top of my to do list...

recon506 (author)harari2008-06-13

I used to live in Rishon-Lezion, until I moved here to the USA when I was 5 and a half years old. Sadly, I forgot all my hebrew, as I speak Russian at home. but yeah, go Israel! Btw, I used to live on Azaid Street. It's a kind of a tiny street branching off of Rotschild, and not many people knew it actually existed.

harari (author)recon5062008-06-23

yeah, me neighborhood is also "invisible". were you born in Israel? rotschild rocks! there so much to do on that boulevard.

recon506 (author)harari2008-06-23

Yeah I was born in good old Israel. Rotschild is awesome. I remember the fish store that was right by the city park. I distinctly remember getting hit by a fish head on my way to a friends house. I also remember an abundance of spent shells and unfired rounds from M16's and UZI's all over the place. When I brought one home my dad got pretty mad and I couldn't sit down for a week after that. Other than that, Rishon was just your typical quiet town out in the back of Tel-Aviv. What do you do for a living? Speaking of which, since I didn't relinquish my Israeli citizenship when I got my US one, I was thinking of maybe going to the army for the prescribed 2 years. My parents think I'm crazy, but I should go through what my friends are gonna go through. Hell, I might even go through it with them together!

crickle321 (author)Switz2007-12-20

Hmm, the translation is pretty interesting though the graphic seems a little misleading. It would be easy to assume (at least to me) it would say something like "Back Off”, “Talk To The Hand” or something related to a button with a big hand... Thanks for translating :-)

Switz (author)crickle3212007-12-20

No problem :) I could mean "come" for eternity and have some sexual innuendo's. That could explain the hand. LOL

crickle321 (author)Switz2007-12-21

oy vay ;p

harari (author)crickle3212008-01-10

yes it means STOP! scouts against violence

lemonie (author)2007-03-14

These are not a good shape for teeth, but it looks very neat.
My thought here is: power the dremel with AC and you've got one of these:

sam (author)lemonie2007-03-14

Most dremels are powered from AC.

lemonie (author)sam2007-03-15

The motor it's self would most likely be DC. I don't know for sure, but this type of motor usually is. If you feed a DC motor AC, it will tend to vibrate rather than turn (as the commecrcial cutter above)

harari (author)lemonie2007-03-17

the dremel above is AC powered ! and it has an AC motor

lemonie (author)harari2007-03-18

You dismantled your Dremel?! What voltage is the motor, stepped-down or straight off the mains supply? L

harari (author)lemonie2007-03-19

i don't really understand the question but it has no transformer, it is connected directly to 220V AC

lemonie (author)harari2007-03-19

(as Mar 15th) I meant that inside the Dremel, the motor may well be DC. I'd thought that you had taken the thing apart to find out the motor was AC. I don't think you have (and that wouldn't be a good idea). Either way, could you post a picture/video of this in action cutting something?

harari (author)lemonie2007-03-31

i will post a video soon, i am just very busy lately

bigpinecone (author)sam2007-03-15

mine isn't and i hate the thing

harari (author)lemonie2007-03-17

that's exactly what i had in mind when i thougt of this project - and my dremel IS an AC powered one.

jtobako (author)lemonie2007-03-14

cast cutters are a little different from regular dremel. they have a back and forth motion that lets the teeth cut hard substances like a plaster cast but not soft things like skin.

BoomGuy (author)2007-03-16

I haven't seen one of those buttons in a long time. I take a cutout disk and use it as a template to make a disk out of a tin can. No teeth makes a good tool for scoring plastic or wood, but not for cutting. I've been trying teeth but haven't found anything strong enough that will be sharp enough. The next thing I will try is cutting out four notches. Maybe the metal from the button will be stronger. In the meantime maybe people can think of other scrap metal that can be used. BoomGuy

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