Intro: Let's Make a Wireless Jigsaw
The word "wireless" is a bit exaggerated, which actually means no wiring is connected or simply is battery operated. Of course I have a "wired" jigsaw which using AC power, sometimes I need to cut thin ply board, I need take out the jigsaw from storage box, plug the wire, and put it back after work, the most trouble is the blowing fan of the jigsaw blows out the saw dusts everywhere, I need a lot of cleanup work even a small cut. So a wireless jigsaw gives me a handy convenience whenever I needed and easy controlled of saw dusts.
Step 1: Prepare the Saw Blade
The most important parts of this jigsaw is the saw blade, this saw blade is originally from my AC jigsaw. All parts using in this instructables are scraped parts except the battery holder. I fixed the saw blade using a piece of copper tube (1/4") which is hammered flat as the holder, drilled two holes in the notch position and screw it with 2 mm set screws with the nuts soldered in back, this facilities changing of blade like the AC jigsaw.
Step 2: The Jigsaw Frame
The frame is built by scraped wooden block, the middle section connected the top with the motor, and the bottom section for the level plate. Screw two L shaped brackets on top of a layer of thin sheet of aluminum, adjusted the gap between the brackets for freely move the saw blade holder. The bottom section cut a notch and fit a U shaped bracket bend with aluminum sheet as the blade guilder.
Step 3: Mount the Motor
The motor was used from RC motor car many years ago, self made two brackets to screw into the upper section of the frame, the crank disc made with copper plate, soldered a copper joint to screw the motor shaft. The battery holder installed in the middle section with a micro switch to control, I found single 18650 battery enough to power, but I parallel it with two.
Step 4: Link Up the Blade Holder
At the end of the blade holder cut out a small notch and drill 2mm hole, insert a 2mm set screw with the nut, solder the nut direct on the notch. Cut a piece of aluminum sheet and fold it as the linkage rod, secure both ends with set screws, add oil in the middle bracket for freely move of blade holder.
Step 5: Add Protective Shield
Cut a piece of plastic from stationery file folder and screw the shield over the crank disc, it prevents hurt when the crank moving.
Step 6: Well Done
Actually tested it can cut smoothly on thin ply about 2-3mm, which fulfilled my needs.