In this instructable, I am going to show you how you can make yourself a cordless Dremel tool under 10$.
This is a portable tool and do anything anywhere between drilling and sanding that a regular dremel tool can do. The body is made out of a 2 inch UPVC pipe and some fibre glass sheet while the tool is powered by a commonly available speed 400 DC motor.
Moreover, I have used 3.7v lithium polymer cells from an old laptop battery to make it a cordless tool so to get the convince of working anywhere is good.
This tool is light weight and have good power to drill holes upto 3mm in almost any material. It can also work as a small router and perform all the tasks as a Dremel tool.
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Step 1: The Motor
To power this tool I am going to use a commonly available speed 545 motor or a speed 400 motor. Well this is a 12v DC motor but I am going to power it at 7.4v because I was able to fit two lithium pollymer cells in the 2 inch PVC pipe and at that voltage the motor have sufficient power.
The motor is then fitted with a motor coupling that is avaliable for these motors. This is a push fitted coupling and need some hammering to get it in place. Its able to grip any shaft up to 3mm.
Step 2: The Main Body
The main body or enclosure is made up of a 2 inch diameter PVC pipe. The pipe is cut down to 6 inch length and then both edges are sanded to make sure they are flat and smooth using a sandpaper.
The PVC pipe forms a cheap but reliable enclosure for this tool and looks great .The best part about that its available in various sizes so you can easily get the required size for to match the size of your motor that you are going to use.
Step 3: End Caps
The end caps for main body are made out of 3mm fibre glass sheet. The diameter is a bit larger than that of the PVC pipe so that i will sand it down later to accurately match the size of the enclosure and give it a smooth finish.
Both the front and the end caps are cut using an adjustable circular saw. The edges are then glued using a super glue to seal the fibre that may come lose later.
Step 4: Motor Mount
The motor mount is made using the same fibre glass end cap cut out of fibre glass sheet and is glued to one end of the casing. Two mounting holes are drilled to mount the motor to the casing using 4 mm screws.
Step 5: Battery Pack
The battery pack is made out of two lithium polymer cells soldered in series to give an output voltage of nearly 7.4v and they have a capacity of 2200 mAh so it will last for good timing.
The battery pack is insulated to ensure that none of the terminals are exposed to short circuit when enclosed in the casing.
Step 6: Putting Everything Together
First off we mounted the motor to the casing and then added a switch in series with the battery pack and the motor . Later I made a hatch on the casing by drilling multiple holes and then sanding it to fit the switch tightly.
The battery Pack is then slides into the casing and the good thing is that it fits perfectly in the casing so no sliding parts inside the case.
A 5mm charging jack is then connected to the battery pack so to recharge the battery pack when needed. This jack is mounted to the rear end cap. The rear end cap is the glued to the case and sanded both end caps to give them a smooth finish.
Step 7: Finishing Touches Painting the Body
Although, PVC pipe and the fibre glass sheet makes the casing look really neat and reliable but I decided to go with a paint job on the casing. First I put on the laters need to be painted on the main body and then used some clear tape to protect any unwanted parts to get painted.
A single coat of blue spray paint is done which seems to get the job done. The tape and the stickers are then removed.
Step 8: Final Results
This ended up as a pretty handy and small tool that replicates a Dremel tool and is equal in nearly all aspects as of an original Dremel tool. This thing is able to drill in anything from wood to fibre glass sheet etc except of metal. This whole project costed me almost nothing and the laptop battery help me to make this a cordless tool.
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