How To Make A Table Saw From A Circular Saw: Save Money

Can you make a table saw from a circular saw? Yes, you absolutely can! This is an affordable and space-saving alternative to buying a dedicated table saw. This guide provides detailed instructions on building your own table saw, covering safety, necessary materials, and step-by-step directions to help you achieve a precise and functional woodworking setup on a budget. This article explains how to do a circular saw table conversion and other ways on how to build a table saw from circular saw.

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Why Build a Table Saw from a Circular Saw?

A table saw is a central tool in any woodworking shop, but high-quality models can be expensive. Building a table saw from a circular saw provides several advantages:

• Cost Savings: Circular saws are generally less expensive than table saws. Building your own can save you a significant amount of money, making it an affordable table saw project.
• Space Efficiency: For those with limited workshop space, a DIY table saw can be designed to fit specific dimensions, offering a space-saving alternative using a circular saw.
• Customization: You can customize the table size, fence design, and other features to perfectly suit your specific needs.
• Recycling and Reuse: This project allows you to repurpose an existing circular saw, promoting resourcefulness and sustainability.

Essential Tools and Materials

Before you begin, gather the necessary tools and materials. This preparation ensures a smooth and efficient build.

Tools

• Circular Saw (obviously!)
• Drill/Driver
• Jigsaw
• Measuring Tape
• Square
• Screwdrivers
• Safety Glasses
• Hearing Protection
• Clamps
• Sander or Sandpaper
• Optional: Router with Straight Bit

Materials

• Plywood (¾ inch thick for the table surface and base)
• Lumber (for the fence and support structure)
• Screws (various sizes for different connections)
• Wood Glue
• T-Track (for miter gauge and fence)
• Hardware (bolts, nuts, washers for securing the circular saw)
• Switch (for controlling the power to the saw)
• Wiring and Electrical Connectors
• Optional: Miter Gauge
• Optional: Featherboards

This list provides a comprehensive overview, adjust quantities based on your specific design and needs.

Design Considerations

Careful planning is crucial for a successful build. Before you start cutting wood, consider these design elements.

Table Size and Dimensions

Determine the size of your table based on the type of projects you plan to undertake and the available space in your workshop. A common size for a small table saw is 24″ x 36″, but feel free to adjust this to your liking.

Circular Saw Mounting

Consider how you will mount the circular saw to the table. Options include:

• Top-Mount: The saw is mounted directly to the underside of the table. This is simpler but reduces cutting depth.
• Suspended Mount: The saw is suspended below the table. This maximizes cutting depth but requires a more complex mounting system.

Fence Design

The fence is critical for accurate cuts. Options include:

• Simple Fence: A straight piece of wood clamped to the table. This is the simplest but least accurate.
• T-Track Fence: A fence that slides along T-tracks, allowing for easy adjustments and repeatable cuts.
• Self-Squaring Fence: A fence designed to automatically align parallel to the blade. This offers the highest accuracy but is more complex to build.

Dust Collection

Consider incorporating a dust collection port to connect a shop vacuum or dust collector. This helps keep your workspace clean and improves air quality.

Safety Features

Safety should be your top priority. Include features such as:

• Blade Guard: A guard to protect your hands from the blade.
• Splitter: A splitter to prevent the wood from pinching the blade and causing kickback.
• Push Stick: A push stick to safely guide the wood past the blade.
• Emergency Stop Switch: An easily accessible switch to quickly shut off the saw in case of an emergency.

Step-by-Step Construction Guide

Follow these steps to build your table saw from a circular saw. This is a homemade table saw guide, so take the time to learn the steps.

Step 1: Build the Table Frame

1. Cut the Plywood: Cut the plywood to the desired table size.
2. Build the Frame: Construct a frame around the perimeter of the plywood using lumber. This frame provides support and rigidity to the table.
3. Attach the Frame: Secure the frame to the plywood using wood glue and screws. Ensure the frame is square and level.
4. Add Internal Supports: Add internal supports to the frame to prevent the table from sagging. These supports should be evenly spaced and securely attached.

Step 2: Mount the Circular Saw

1. Cut the Opening: Cut an opening in the table to accommodate the circular saw blade. The size and shape of this opening will depend on the size of your saw blade.
2. Create a Mounting Plate: Create a mounting plate from plywood or metal. This plate will attach to the underside of the table and hold the circular saw in place.
3. Attach the Saw to the Plate: Securely attach the circular saw to the mounting plate using bolts, nuts, and washers. Ensure the saw is properly aligned with the table surface.
4. Attach the Plate to the Table: Attach the mounting plate to the underside of the table. This can be done with screws or bolts.

Step 3: Build the Fence System

1. Install T-Tracks: Install T-tracks on the table surface, parallel to the blade. These tracks will guide the fence and allow for easy adjustments.
2. Build the Fence: Construct a fence from lumber. The fence should be straight and square, and it should be designed to slide along the T-tracks.
3. Attach the Fence to a Slider: Attach the fence to a slider that fits into the T-tracks. This slider should allow for smooth and easy movement of the fence.
4. Add a Locking Mechanism: Add a locking mechanism to the fence to hold it securely in place during cuts. This mechanism can be as simple as a clamp or as complex as a lever-operated cam lock.

Step 4: Add Safety Features

1. Install a Blade Guard: Install a blade guard to protect your hands from the blade. The guard should be adjustable to accommodate different cutting heights.
2. Install a Splitter: Install a splitter to prevent the wood from pinching the blade and causing kickback. The splitter should be slightly thinner than the blade and should be positioned directly behind the blade.
3. Create a Push Stick: Create a push stick to safely guide the wood past the blade. The push stick should be long enough to keep your hands away from the blade.
4. Install an Emergency Stop Switch: Install an easily accessible emergency stop switch to quickly shut off the saw in case of an emergency.

Step 5: Wiring and Electrical Connections

Important Safety Note: If you are not comfortable working with electricity, consult a qualified electrician.

1. Mount the Switch: Mount the switch in an easily accessible location on the table saw.
2. Wire the Switch: Wire the switch to the circular saw’s power cord. The switch should interrupt the power supply to the saw.
3. Add a Power Cord: Add a power cord to the switch. The power cord should be long enough to reach a power outlet.
4. Test the Wiring: Test the wiring to ensure it is working properly. Use a multimeter to check for continuity and voltage.

Step 6: Final Adjustments and Testing

1. Align the Blade: Ensure the blade is perfectly aligned with the fence. Use a square to check the alignment.
2. Adjust the Fence: Adjust the fence to ensure it is parallel to the blade. Use a measuring tape to check the distance between the fence and the blade at multiple points.
3. Test the Saw: Test the saw by making several cuts. Check the accuracy of the cuts and make any necessary adjustments.
4. Sand and Finish: Sand any rough edges and apply a finish to protect the wood.

Advanced Features and Upgrades

Once you have a basic table saw built, you can add advanced features and upgrades to improve its functionality and accuracy.

Miter Gauge

A miter gauge allows you to make accurate angled cuts. You can purchase a miter gauge or build your own.

Featherboards

Featherboards hold the wood firmly against the fence, improving accuracy and safety. You can purchase featherboards or build your own.

Outfeed Table

An outfeed table provides additional support for long pieces of wood, preventing them from tipping or falling off the table.

Dust Collection System

A dust collection system helps keep your workspace clean and improves air quality. You can connect a shop vacuum or dust collector to the table saw.

Safety Considerations

Working with power tools can be dangerous. Always follow these safety precautions:

• Wear Safety Glasses: Protect your eyes from flying debris.
• Wear Hearing Protection: Protect your ears from the loud noise of the saw.
• Use a Blade Guard: Keep your hands away from the blade.
• Use a Push Stick: Guide the wood past the blade safely.
• Never Reach Over the Blade: Avoid reaching over the blade to retrieve wood.
• Disconnect Power Before Adjustments: Always disconnect the power cord before making any adjustments or repairs.
• Stay Focused: Pay attention to what you are doing and avoid distractions.
• Keep Your Workspace Clean: A clean workspace reduces the risk of accidents.
• Know Your Saw: Read the owner’s manual and familiarize yourself with the saw’s features and limitations.

Circular Saw Table Mount Options

There are different ways to mount a circular saw.

Top-Mount:

Simpler installation with the saw attached directly to the table’s underside.
Reduces maximum cutting depth due to the saw’s position.

Suspended Mount:

Maximizes cutting depth by suspending the saw below the table surface.
Requires a more complex mounting system to ensure stability and alignment.

Plate Mount:

Involves attaching the circular saw to a separate plate, then mounting the plate under the table.
Offers a balance between ease of installation and maintaining a decent cutting depth.

Direct Mount:

Attaching the circular saw directly to the underside of the table.

Circular Saw to Table Saw Jig

Making a jig can greatly improve your experience with circular saw table conversion.

Simple Crosscut Jig:

Allows for making accurate 90-degree cuts.
Consists of a base that slides along the fence with an attached fence for holding the workpiece.

Miter Jig:

Enables angled cuts with precision.
Features an adjustable angle setting for making consistent miter cuts.

Taper Jig:

Used for creating tapered cuts in woodworking projects.
Secures the workpiece at a specific angle to achieve the desired taper.

Interpreting Plans for DIY Table Saw Builds

Deciphering Schematics:
Learn how to read technical drawings of table saw projects.
Familiarize yourself with symbols, dimensions, and views to understand the construction plan.

Material Selection:
Choose the correct materials by examining the plans.
Refer to specific wood types, hardware sizes, and quantities as detailed.

Sequencing the Build:
Create a step-by-step build order.
Break the project into stages, like building the frame, mounting the saw, and adding safety features.

Examining Measurements:
Verify all measurements to ensure a proper fit.
Pay careful attention to dimensions for cutting pieces and mounting hardware.

Frequently Asked Questions (FAQ)

Q: What is the best type of circular saw to use for a table saw conversion?
A: A corded circular saw with a powerful motor (13 amps or more) and a blade size of 7 1/4 inches is ideal. Look for a saw with a flat motor housing for easier mounting.

Q: Can I use a cordless circular saw?
A: While possible, cordless circular saws may not provide the consistent power and runtime needed for extended use as a table saw. Battery life can be a limiting factor.

Q: How much does it cost to build a table saw from a circular saw?
A: The cost can vary depending on the materials you use and the features you add. On average, expect to spend between $100 and $300, assuming you already own a circular saw.

Q: What are the most important safety features to include?
A: A blade guard, splitter, push stick, and emergency stop switch are essential for safe operation.

Q: How do I ensure accurate cuts?
A: Use a high-quality fence system, carefully align the blade with the fence, and use featherboards to hold the wood firmly against the fence.

Q: What is kickback, and how can I prevent it?
A: Kickback occurs when the wood pinches the blade and is thrown back towards the operator. Prevent kickback by using a splitter, featherboards, and a push stick.

Q: Where can I find circular saw table conversion plans?
A: Numerous websites, woodworking forums, and YouTube channels offer free and paid DIY table saw plans.

Q: What maintenance is required for my homemade table saw?
A: Regularly clean the saw, lubricate moving parts, check the blade for sharpness, and inspect the wiring for damage.

Q: Is building my own table saw worth the effort?
A: If you enjoy DIY projects and are looking for an affordable and customizable table saw solution, building your own can be a rewarding experience. However, if you prioritize convenience and precision, purchasing a pre-built table saw may be a better option.

By following this guide, you can build a functional and affordable table saw from a circular saw. Remember to prioritize safety, plan carefully, and take your time during the construction process. Good luck!