DIY Mini Circular Saw

In this project, I will show you how to build a compact and useful mini circular saw using easily available materials. This tool is perfect for small DIY projects like cutting plywood, plastic, and light materials with better precision.

The idea is to convert a simple DC motor into a functional cutting tool by creating a custom saw blade from a pizza cutter and building a sturdy base with a motor mount. Along the way, we also add a handle and a protective guard to make the tool safer and easier to use.

This project is budget-friendly and can be made with basic tools, making it ideal for hobbyists, students, and DIY enthusiasts.

Note: Always follow safety precautions while working with cutting tools and power sources.

Let’s get started! 🔧

Here’s a complete list of materials required to build the mini circular saw:

1. DC motor (12V)
2. Pizza cutter (for making the saw blade)
3. Plywood pieces (for base and support)
4. Metal sheet or strip (for mounting bracket)
5. Epoxy clay (for fixing blade to motor shaft)
6. Push button switch
7. DC power connector (female jack)
8. Power source (battery or adapter)
9. Wires (for electrical connections)
10. Nuts and bolts (for mounting parts)
11. Small screws

Start by marking the required dimensions on the plywood using a ruler and marker. Draw straight, clear lines to ensure accurate cutting. This base will support all the components, so keep the size slightly larger than your motor and blade setup.

Next, carefully cut along the marked lines using a jigsaw. Make sure to follow the lines precisely to get a clean and even shape.

After cutting, drill holes at the marked positions, cut & make gape in plywood for saw blade.

Finally, smooth the edges if needed. Your plywood base is now ready for the next step.

Remove the blade from the pizza cutter using plier.

Once the blade is removed, secure it firmly in a vice or hold it steadily using pliers. Using a metal file, begin shaping small, evenly spaced teeth around the edge of the blade. Work slowly and maintain consistent angles to ensure smooth cutting performance.

Continue filing until the entire edge has sharp teeth. Try to keep the size and spacing uniform for better balance and efficiency.

After finishing, clean the blade and check for any uneven edges. Your custom mini saw blade is now ready to

Take the prepared saw blade and position it on the shaft of the DC motor. Make sure the blade is centered properly to avoid wobbling during rotation.

Now mix a small amount of epoxy clay and apply it around the joint where the motor shaft meets the blade. Build it evenly around the center to hold the blade firmly in place.

Carefully adjust the alignment before the epoxy starts to harden. Spin the blade gently by hand to check if it rotates smoothly without imbalance.

Allow the epoxy clay to cure completely as per its setting time. Once hardened, the blade will be securely attached to the motor and ready for use.

To securely attach the motor to the base, create a custom metal mounting bracket.

Start by taking a thin metal strip and drilling holes at both ends. These holes will be used later for fixing the bracket to the base. After drilling, use pliers to trim and adjust the shape if needed.

Next, carefully bend the metal strip into a curved (U-shaped) form so it can hold the motor tightly. Make sure the curve matches the diameter of your motor for a snug fit.

Place the shaped metal bracket onto the base and mark the hole positions using a marker. Then drill corresponding holes in the base.

This metal mount will act as a strong holder to keep the motor stable during operation.

Place the motor inside the curved metal bracket you made in the previous step. Adjust it so the motor sits firmly and is properly aligned with the blade position.

Now position the bracket on the base, matching the holes you drilled earlier. Insert nuts and bolts through the bracket and base, then tighten them securely.

Make sure the motor is held tightly without any movement. Proper alignment is important to ensure smooth and vibration-free operation of the mini circular saw.

Now it’s time to improve safety and usability by adding a handle and a blade protector.

Start by drawing the handle shape on a piece of plywood. Cut it carefully using a jigsaw or hand saw. Once cut, smooth the edges using sandpaper and apply paint if desired for a better finish.

Next, take a thin metal sheet and shape it into a curved guard to cover part of the blade. This will act as a safety protector while cutting.

Finally, fix both the plywood handle and metal blade protector onto the main structure using screws or bolts. Ensure everything is tightly secured and properly aligned.

This step makes your mini circular saw safer to use and easier to handle.

Start by preparing the wires from the motor and stripping their ends if needed. Take your push button switch and DC power connector, and identify their terminals.

Connect one wire from the motor to the switch, and then connect the switch to the power input. This will allow you to control the ON/OFF function easily. Make sure all connections are tight and secure.

Use soldering or twist the wires firmly, then insulate them properly using tape.

Finally, position the switch in a convenient place on the body and fix it securely. Now your mini circular saw has a proper power control system ready for operation.

Now connect a 12V power supply to the DC power connector. Double-check all wiring connections before turning it on to ensure everything is secure and properly insulated.

Press the switch to power the motor. The blade should start rotating smoothly. Observe carefully for any wobbling or unusual vibration and fix alignment if needed.

Once everything is running properly, your mini circular saw is ready to use. You can now start cutting small wooden pieces carefully and efficiently.

⚠️ Always use safety precautions while operating, such as keeping hands away from the blade and wearing protective gear.