In this Instructable we'll create a simple footswitch for turning on/off a mains powered tool (dremel/drill press/etc.).
Bill of materials:
- 2X 11x30cm boards
- Momentary switch (e.g., door bell switch)
- Mains plugs (male and female)
- Power cord
You should take into account the power specs for the switch/cord and power tool (power of switch/cord > power of tool).
- Router/Jigsaw/something that cuts holes
Step 1: Body
The body is composed by two pieces of wood:
- A hole should be cut into one of the boards to insert the switch.
- On the second board, and below the hole on the first, use the router to create a small depression in the wood. This depression will be used to accommodate the wiring.
- Use the router to cut a groove to allow the wiring to get out of the body. This groove should be cut in such a way that the cord is not loose inside it.
- Drill some holes for the screws on the second board.
Step 2: Electrical Stuff
To save space and to keep the number of connections to a minimum do the following:
- Peal off the outside insulation of the power cord somewhere in the middle (see youtube video).
- Cut on of the wires in half (not the ground one).
- Stick the two newly created ends into the switch.
- Slide the outside insulation so that the remaining wires are not exposed.
Attach male and female plugs to both ends of the cord.