How To Make Table Saw With Circular Saw: Save Money

Are you looking for a cheap table saw alternative? Yes, you can make a table saw from a circular saw! This guide provides step-by-step instructions on how to build a table saw from a circular saw, offering a budget-friendly option for woodworking enthusiasts. We’ll cover circular saw table conversion, homemade table saw construction, creating a circular saw table saw jig, and even provide circular saw table plans. This DIY table saw project is a great way to save money and create a valuable tool for your workshop.

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Why Build a Table Saw from a Circular Saw?

Building your own table saw using a circular saw as the main component provides several advantages. Let’s explore why this project could be right for you.

• Cost Savings: Table saws can be expensive. Building one with a circular saw is a significantly cheaper alternative. Instead of spending hundreds (or even thousands) on a professional table saw, you only pay for the materials needed to build the table and mounting system.
• Customization: A homemade table saw can be tailored to your specific needs and workspace. You decide the size, features, and overall design.
• Accessibility: If you already own a circular saw, you’re halfway there! This project re-purposes an existing tool, turning it into something even more useful.
• Learning Experience: Building a table saw is a fantastic way to improve your woodworking skills and learn about tool mechanics.
• Space Efficiency: You can build a smaller table saw, suited for limited spaces.

Essential Tools & Materials

Before you start your DIY table saw project, gather the necessary tools and materials. Careful preparation is key to a successful build.

Tools

• Circular Saw: The heart of your project. Ensure it’s in good working condition.
• Drill/Driver: For screwing together the table components.
• Jigsaw or Circular Saw (for table cuts): For cutting the plywood or MDF for the table surface and frame.
• Measuring Tape: Accuracy is crucial.
• Square: To ensure right angles for accurate cuts.
• Safety Glasses: Protect your eyes from sawdust and debris.
• Hearing Protection: Power tools can be noisy.
• Clamps: To hold pieces together while gluing and screwing.
• Screwdrivers/Sockets: For securing the circular saw to the mounting plate.
• Router (Optional): For creating clean edges and grooves for accessories.

Materials

• Plywood or MDF (for the table): ¾ inch thick plywood is recommended for its strength and stability. MDF is a cheaper option but may not be as durable.
• Lumber (for the frame): 2x4s or similar lumber for constructing a sturdy frame.
• Mounting Plate (Steel or Aluminum): A flat, rigid plate to secure the circular saw beneath the table. Steel is very durable, aluminum is lighter.
• Screws: Wood screws for the frame and table, machine screws for the mounting plate.
• Wood Glue: For strengthening joints.
• T-Track (Optional): For adding accessories like a miter gauge or fence.
• Hardware Cloth (Optional): For Dust Collection.
• Switch and Electrical Wiring: For safely powering the saw.
• Push Stick/Block: Essential for safe operation.

Designing Your DIY Table Saw: Circular Saw Table Plans

Planning is critical. Consider the size of your workspace and the types of projects you plan to undertake. Here’s what you should think about when creating your circular saw table plans:

• Table Size: Decide the dimensions of your table saw based on your workspace and typical project sizes. A common size is 24″ x 36″, but adjust as needed.
• Table Height: Aim for a comfortable working height, typically around 36 inches.
• Fence System: Determine the type of fence you want. A simple fence clamped to the table works, or you can build a more sophisticated T-track system.
• Mounting System: How will you secure the circular saw? Consider a fixed mount or a removable one for easy access.
• Dust Collection: Plan for dust collection to keep your workspace clean and improve visibility.
• Safety Features: Include features like a blade guard, splitter, and anti-kickback pawls to enhance safety.

Here’s a basic example of potential table dimensions:

Component	Dimension
Table Length	36 inches
Table Width	24 inches
Table Height	36 inches
Frame Material	2×4 lumber
Tabletop	¾ inch Plywood/MDF

Step-by-Step Guide: Building Your Homemade Table Saw

Now, let’s get to the actual build. These steps outline the process of creating your DIY table saw:

Step 1: Construct the Table Frame

1. Cut the lumber for the frame to the desired dimensions. Ensure all cuts are square.
2. Assemble the frame using wood glue and screws. Use clamps to hold the pieces together while the glue dries.
3. Reinforce the corners of the frame with corner braces for added stability.

Step 2: Prepare the Tabletop

1. Cut the plywood or MDF to the desired dimensions for the tabletop.
2. If you plan to install T-tracks, rout the necessary grooves into the tabletop before attaching it to the frame.
3. Sand the tabletop smooth to remove any splinters or rough edges.
4. Attach the Tabletop to the Frame. Use wood glue and screws. Make sure the table top is aligned correctly.

Step 3: Create the Mounting Plate

1. Measure the base of your circular saw and determine the size of the mounting plate. The plate should be large enough to fully support the saw.
2. Cut the steel or aluminum plate to size.
3. Drill holes in the mounting plate to match the mounting holes on the base of your circular saw.
4. Counter sink the holes so that the screws will not protrude above the surface of the plate.

Step 4: Mount the Circular Saw

1. Attach the circular saw to the mounting plate using machine screws. Ensure the saw is securely fastened.
2. Position the mounting plate on the underside of the tabletop, aligning the saw blade with the desired cutting line.
3. Carefully trace the outline of the mounting plate onto the tabletop.
4. Using a jigsaw or circular saw, cut an opening in the tabletop for the mounting plate. Make sure the opening is slightly larger than the plate for easy removal and adjustment.
5. Secure the mounting plate to the underside of the tabletop using screws.

Step 5: Install the Fence

1. Decide on the type of fence you want to use. A simple fence can be made from a straight piece of wood clamped to the table.
2. For a more advanced fence, install T-tracks along the front and back edges of the table.
3. Build a fence that slides along the T-tracks and can be locked into position. Ensure the fence is square to the blade.

Step 6: Add Safety Features

1. Install a blade guard to protect your fingers from the spinning blade. You can purchase a ready-made blade guard or fabricate one yourself.
2. Add a splitter behind the blade to prevent the wood from pinching and causing kickback.
3. Use anti-kickback pawls to further reduce the risk of kickback.
4. Always use a push stick or push block when making cuts.

Step 7: Implement Dust Collection (Optional)

1. Build a small enclosure under the table saw surrounding the blade area.
2. Cut a hole in the enclosure that is the correct size for your vacuum hose.
3. You can add hardware cloth to create a filter.

Step 8: Wiring the Switch

1. Mount a switch to the table saw frame in an easy to reach location.
2. Wire the switch into the power cord of the circular saw. Be sure to follow all electrical safety regulations.
3. Test the switch to ensure it works properly.

Circular Saw Table Mount: Ensuring Stability

The way you mount your circular saw to the table is crucial for stability and accuracy. Here are a few approaches to consider:

• Fixed Mount: The saw is permanently attached to the mounting plate. This is a simple and secure method.
• Removable Mount: The saw can be easily removed for handheld use. This offers versatility but requires a more complex mounting system.
• Adjustable Mount: Allows you to adjust the height of the blade above the table surface. This is useful for making dado cuts.

Enhancing Your Homemade Table Saw

Once you’ve built the basic table saw, consider adding features to improve its functionality:

• Miter Gauge: A miter gauge allows you to make accurate angled cuts.
• Feather boards: Feather boards keep the wood tight against the fence.
• Outfeed Table: An outfeed table supports long pieces of wood as they exit the saw.
• Zero Clearance Insert: A zero clearance insert minimizes tear-out and improves cut quality.

Safety First: Operating Your DIY Table Saw

Safety is paramount when using any power tool. Follow these guidelines to prevent accidents:

• Always wear safety glasses and hearing protection.
• Never operate the saw without a blade guard and splitter in place.
• Use a push stick or push block to guide the wood through the blade.
• Keep your hands away from the blade.
• Never reach over the blade.
• Ensure the work area is well-lit and free of clutter.
• Disconnect the power cord before making any adjustments or repairs.
• Never force the wood through the blade. Let the saw do the work.
• Be aware of the risk of kickback and take steps to prevent it.
• Don’t wear loose clothes or jewelry that could get caught in the saw.
• Take breaks to avoid fatigue, which can lead to accidents.

Optimizing Your Cuts: Circular Saw Table Saw Jig

Using a jig can greatly improve the accuracy and safety of your cuts. Here are a few useful jigs to consider:

• Crosscut Sled: A crosscut sled allows you to make perfectly square cuts.
• Miter Sled: A miter sled is used for cutting accurate angles.
• Tapering Jig: A tapering jig is used for cutting tapers on legs or other projects.
• Dado Jig: A dado jig allows you to make precise dado cuts.

Troubleshooting Common Issues

Even with careful planning, you may encounter some issues during the build or operation of your DIY table saw. Here are some common problems and solutions:

• Vibration: Ensure the saw is securely mounted and the table is stable. Add weight to the base of the table to reduce vibration.
• Inaccurate Cuts: Check the alignment of the fence and blade. Use a square to ensure the fence is perpendicular to the blade.
• Kickback: Use a splitter and anti-kickback pawls. Avoid forcing the wood through the blade.
• Tear-out: Use a zero clearance insert or score the wood before cutting.
• Saw Not Powerful Enough: Circular saws have limitations. Reduce the cutting depth, use a sharp blade, or consider upgrading to a more powerful saw.

The Budget Table Saw Build: Keeping Costs Down

One of the main reasons for building a DIY table saw is to save money. Here are some tips for keeping your budget in check:

• Use reclaimed or recycled materials.
• Shop around for the best prices on lumber and hardware.
• Buy used tools when possible.
• Build your own fence and jigs instead of buying them.
• Keep the design simple and avoid unnecessary features.

Is a DIY Table Saw Right For You? Considerations.

Before diving in, consider your skill level, available time, and the types of projects you plan to tackle. A DIY table saw isn’t always the perfect solution for everyone.

Skill Level

This project requires basic woodworking skills, including measuring, cutting, drilling, and assembling. If you are new to woodworking, consider starting with a simpler project before attempting a table saw build.

Time Commitment

Building a table saw takes time and effort. Plan to spend several days or even weeks on the project, depending on your skill level and the complexity of the design.

Project Requirements

A DIY table saw is suitable for smaller projects and hobbyist use. If you need a table saw for heavy-duty, professional work, a commercially manufactured table saw may be a better choice.

Circular Saw Table Conversion: A Rewarding Project

Building a table saw from a circular saw is a rewarding project that can save you money and improve your woodworking skills. By following these steps and tips, you can create a valuable tool for your workshop that will provide years of reliable service. Remember to prioritize safety and take your time to ensure accurate cuts and a stable construction.

Frequently Asked Questions (FAQ)

• What is the best type of circular saw to use for a table saw conversion? A corded circular saw with a powerful motor (13 amps or higher) is recommended. Cordless saws can be used, but battery life may be a limiting factor.
• Can I use a cheap circular saw for this project? While possible, a higher-quality saw will provide better accuracy and durability.
• Who is this project suitable for? Woodworkers with basic skills and a desire to save money.
• What are the main safety concerns with a DIY table saw? Kickback, blade exposure, and dust inhalation. Always use safety equipment and follow safe operating procedures.
• What is the best material for the table top? ¾ inch thick plywood is a good balance of cost, strength and weight.
• How do I ensure my fence is square to the blade? Use a precision square to check and adjust the fence.
• Where can I find circular saw table plans? Online woodworking forums, DIY websites, and YouTube are great sources for plans.
• How long will it take to build a table saw from a circular saw? Depending on the complexity of the design, it can take anywhere from a weekend to several weeks.
• Is a DIY table saw as accurate as a store-bought one? With careful construction and setup, a DIY table saw can be very accurate, but it may require more fine-tuning.
• Can I use a smaller circular saw (e.g., 5 1/2 inch) for this project? Yes, but be aware that the cutting capacity will be limited.