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TedsWoodworking Plans and Projects

How to Make a Table Saw with A Circular Saw – Steps to Follow

You can make a table saw using a regular circular saw in just a few steps. There are different ways to go about this, but some make better homemade table saws than others. You cannot depend on some methods since they make table saws challenging to make the depth adjustments.

Such a version also makes it almost impossible to tilt the saw when it is necessary. Therefore, I want to show you the best tips on how to make a table saw with a circular saw. We have provided every little detail to help you be accurate with every bit of the process.

Materials Needed

  • Plywood, melamine, or a board for legs and tabletop
  • Circular saw
  • Wood screws with flat head (50mm and 16mm)
  • Power zip
  • Circular saw
  • Zip tie

Tools You Need

  • Band saw
  • Drill and bits
  • Square
  • Clamps
  • A file

How to Make a Table Saw with A Circular Saw

Step 1: Preparation

Begin by removing the shoe, blade guard, and adjustment mechanisms from your circular saw. Make sure your choice of the circular saw to use here is excellent. Not all circular saws provide the desired results. Make sure it is good quality and produces less noise.

Drill 54 mm holes in your circular saw base. These will be the new fitting points to the board. Make sure you clean the burs left after drilling the holes. When you prepare well for the steps to come, everything will fall into place more smoothly and efficiently.

Step 2: Experiment and cut the right shape of the plywood

This is mostly an experimental project, and you should experiment with the shape of plywood you need for your table saw by first making some cardboard cutouts. When you finally make the right shape with your cardboards, and find that they fit into your saw nicely, make the same shaped cutouts on your plywood. The cardboard cutouts help you visualize the shape of the plywood you need.

Once you have the exact shape of cardboard cutouts, use them to draw the same shape on the plywood, then cut along the drawn lines. It will help you make more accurate cuts. Use a band saw to cut out the plywood.

Step 3: Attach the pieces to the circular saw

When you are done creating the pieces, check how they fit around the circular saw by just holding them in their rightful positions by clamps. Make sure that the alignment is excellent, checking that the saw blade is parallel to the plywood.

Consider an attachment method that can still allow you to get the circular saw out without disassembling the bracket. That way, you will even manage to get it back once you glue it together.

Also, glue and dowel the bracket on just one side and use screws on the other side, at least temporarily. That way, you can have room for changing anything when you need to do so. You can use the hole for the depth adjustment since it is the only existing mounting hole available on the saw.

If the mount on the other side of the saw is small, cut a small piece of wood to fit around it, then screw it in. make sure the only method you use to attach this is by screwing it in because you will need to get the saw out. Therefore, you can unscrew it whenever you need to get the saw out.


YouTube Video On How to Make a Table Saw with A Circular Saw

Step 4: How to make the saw to lock at a particular depth

Create a mechanism for locking the saw at a particular depth. You can achieve that by carving a piece of wood clamped to the mount with a knob. It would be best if you had a part with a measurement of about 2×4.

Use a jigsaw to cut a slot out of it, then fit it in place. Just make sure there are a knob and a piece of plywood in position behind it already. Screw it in place, and you are done.

Step 5: Mount hinges

The hinges will help create the tilt mechanism. Begin this step by routing some grooves so that the hinges’ pin can fit in. also, you need cavities for the part of the mechanism to in.

That way, you will get a little more depth of cut out of the saw. You can use the door hinges, but you will have to drill a few extra holes on them to accommodate the holes’ closeness in the hinge pin. Then drill holes and screw the hinges.

Step 6: Positioning the saw on a tabletop

You can also use laminated particleboard known as melamine for the table saw top. You can use one that is 1.8 cm thick, 50cm-wide, and 80 cm long. If you can find a new one, the better. But you can also use an old one so long as it is still in the right shape. The board should be straight with all edges perfectly square. Then you can put the circular saw in your preferred place on the board. Where you set, it may depend on your personal preference.

You can have thirty centimeters from the front to the saw. However, the best part to put it is a place where it is squared to the table. When you find the right place to put your saw on the tabletop, mark the fixing points.

Predrill the points and screw in the saw with five 16 mm flat-headed screws until it is steadfastly held into place. The 16mm screws are the most suitable for this task since they give a more holding surface, and they sit better on the flat circular saw base. Make sure you cut a gap in the melamine board for the blade.

Final Verdict

That is how to make a table saw with a circular saw. With these steps, you will be able to make it That is how to make a table saw with a circular saw. With these steps, you will be able to make it happen. So long as you have the right tools and materials and follow the fitting instructions to the later, you will end up with a reliable homemade table saw. If you miss a step, it may not turn out to be what you expect. So, make sure you do it right.

Relevant Resources

Last update on 2020-12-01 at 04:43 / Affiliate links / Images from Amazon Product Advertising API

Alvin V.Stone

I’m a DIY enthusiast and run a woodshop. I created this blog to provide you with reliable information concerning power saws so that you can do your work best. Not only do I provide power saw guide and reviews but also other resources that help you take your projects to a higher level.