I have a paper cutter at home which I use for many activities that would probably void its warranty. Thankfully, I purchased it for a low price at a thrift store, so there was no warranty to begin with. The other day I was cutting some sheet metal, when it broke. Here's an instructable on how to repair it so that's even stronger and less prone to breaking.
Pictured in this step is the end product and the broken piece of the previous cutter. The final cutter uses hardwood as opposed to the inexpensive MDF (medium density fiberboard) in the original.
Step 1: Cut to Size
In this step, cut the board to size. I would have used a miter box, but it was too narrow, so I ended up using some blocks and clamps to make a straight cut.
Step 2: Cut the Edge
- A mortising bit, because of how they're machined they are more expensive than regular drill bits.
- To create an even edge, I used a drill press, two wood blocks, and clamps.
- I pushed the wood along the mortise bit as it spun to create the edge.
- The final edge was rough because there was some vibration.
Step 3: Drill Holes
- Flip the board and trace holes for the handle. Make sure the handle-blade is close to the wood before tracing. To make a straight drill, use a center-punch to create a dent. I used a tungsten carbide scribing tool for this.
- Drill the holes.
- Flip over and drill some counter-holes for the screw edges.
- Trace the blade holes.
- Drill the blade holes.
Step 4: Add Legs
- Add glue to wooden legs.
- Put the legs on wood.
- Add rubber feet to the legs.
- Flip over and apply weight to the wood.
Step 5: Finishing Touches
- Added 1/3 bee wax + 1/3 walnut oil + 1/3 mineral oil finish.
- Cut a relief for hand using a scroll saw.
- Added a handle stop using a screw and silicone tubing.