How To Make a Table Saw With Circular Saw: Beginners Guide

Can you make a table saw from a circular saw? Yes, you absolutely can! This guide walks you through the process of building your own DIY table saw using a circular saw. A circular saw table conversion can be a cost-effective way to get the functionality of a table saw without the hefty price tag. This homemade table saw project is perfect for hobbyists and DIY enthusiasts looking for a table saw alternative. This article will show you how to build table saw using circular saw.

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Why Build a Table Saw From a Circular Saw?

There are several reasons why someone might choose to embark on a circular saw to table saw modification project:

• Cost Savings: Table saws can be expensive. Converting a circular saw is an inexpensive table saw alternative.
• Space Saving: If you have limited shop space, a circular saw table offers a smaller footprint than a full-sized table saw.
• DIY Satisfaction: Building something yourself is rewarding!
• Portability: A well-designed circular saw table can be more portable than a traditional table saw.
• Learning Experience: You’ll gain valuable woodworking and fabrication skills.

Planning Your DIY Table Saw

Before you start cutting wood and assembling your shop-made table saw, careful planning is essential. This will ensure a safer and more functional finished product.

Gathering Materials and Tools

You’ll need the following materials:

• Circular Saw: Choose a corded model for consistent power. Consider the size and blade diameter.
• Plywood or MDF: ¾-inch thick plywood or MDF for the table surface and base. Thicker material adds stability.
• Lumber: For framing and supports (2x4s are a common choice).
• Hardware: Screws, bolts, nuts, washers.
• T-Track: For miter gauge and fence attachment.
• Switch and Wiring: For safe and convenient power control.
• Blade: A good quality table saw blade.
• Optional: Dust collection port, miter gauge, rip fence materials.

Here’s a list of tools you’ll need:

• Circular Saw (the one you’re converting!)
• Drill/Driver
• Jigsaw or Router
• Measuring Tape
• Square
• Safety Glasses
• Hearing Protection
• Clamps
• Wrench/Socket Set
• Wire Strippers/Crimpers

Designing Your Table

Consider these factors when designing your table:

• Table Size: Determine the desired table size based on your typical projects and available space. A common size is 24″ x 36″, but adjust as needed.
• Circular Saw Mounting: Plan how you’ll securely mount the circular saw to the underside of the table.
• Fence System: Decide on the type of fence you’ll use (e.g., a simple fence clamped to the table, a T-track fence, or a more elaborate self-squaring fence).
• Miter Slot: Plan for a miter slot if you intend to use a miter gauge.
• Dust Collection: Integrate a dust collection port if you have a dust collector.
• Safety Features: Consider adding features like a blade guard or push stick storage.

Sample Table Dimensions

Dimension	Size (Inches)
Table Top Length	36
Table Top Width	24
Table Height	34
Fence Length	30

These are just example dimensions. Adjust them to fit your needs and the size of your circular saw.

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

Follow these steps to construct your table saw. Always prioritize safety and wear appropriate safety gear.

Step 1: Building the Table Frame

1. Cut the Frame Pieces: Cut the lumber to the desired lengths for the table frame. A basic rectangular frame is sufficient.
2. Assemble the Frame: Join the frame pieces using screws and wood glue. Ensure the frame is square. Use clamps to hold the pieces together while the glue dries.
3. Add Support Rails: Attach support rails to the inside of the frame. These rails will support the table top and provide a place to attach the circular saw mounting platform.

Step 2: Creating the Table Top

1. Cut the Table Top: Cut the plywood or MDF to the desired size for the table top.
2. Cut the Circular Saw Opening: Carefully measure the base plate of your circular saw. Use a jigsaw or router to cut an opening in the table top that is slightly larger than the base plate. Precision is key here!
3. Install T-Track (Optional): If you’re using T-track for a miter slot or fence system, route or cut the necessary channels and install the T-track.

Step 3: Mounting the Circular Saw

This is the most critical step. Securely mounting the circular saw is crucial for safety and accuracy.

1. Build a Mounting Platform: Create a platform from plywood or MDF to which you’ll attach the circular saw. This platform should be slightly smaller than the opening in the table top.
2. Attach the Circular Saw: Securely attach the circular saw to the mounting platform. You can use bolts, screws, or clamps. Ensure the blade is perpendicular to the table top. Consider using the existing holes in the saw’s base plate.
3. Attach the Mounting Platform to the Table: Attach the mounting platform (with the circular saw attached) to the support rails inside the table frame. Ensure the blade is centered in the opening in the table top.
4. Adjust Blade Height: Devise a mechanism to adjust the blade height. This could involve a simple wedge system or a more elaborate threaded rod system.

Step 4: Building the Fence

A good fence is essential for accurate cuts.

1. Choose a Fence Design: Select a fence design that suits your needs. Options include:
   • Simple Fence: A straight piece of wood clamped to the table.
   • T-Track Fence: A fence that slides along a T-track.
   • Self-Squaring Fence: A more complex fence that automatically aligns to the blade.
2. Build the Fence: Construct the fence according to your chosen design. Use sturdy materials and ensure it’s straight and square.
3. Attach the Fence to the Table: Attach the fence to the table using clamps, T-track hardware, or other suitable methods.

Step 5: Adding Safety Features

Safety is paramount!

1. Install a Switch: Install a switch to easily turn the saw on and off. Wire the switch according to local electrical codes.
2. Consider a Blade Guard: While challenging to implement on a DIY table saw, a blade guard is a valuable safety feature.
3. Make Push Sticks: Create several push sticks to keep your hands away from the blade.
4. Add an Anti-Kickback Device: Research and consider adding an anti-kickback device to prevent the workpiece from being thrown back at you.

Step 6: Adding Dust Collection (Optional)

1. Create a Dust Port: Cut a hole in the table base for a dust collection port.
2. Connect to Dust Collector: Attach a hose from your dust collector to the dust port.
3. Enclose the Blade: Try to enclose the blade area as much as possible to improve dust collection efficiency.

Different Circular Saw Table Saw Jig Designs

There are countless variations on the basic circular saw table. Here are a few ideas:

• Tiltable Table: Design the mounting system to allow the circular saw to tilt for bevel cuts.
• Portable Table: Build a smaller, lightweight table with handles for easy transport.
• Folding Table: Create a folding table for compact storage.
• Miter Gauge: Incorporate a miter gauge for accurate angle cuts.

Maximizing Safety When Using Your DIY Table Saw

• Always Wear Safety Glasses and Hearing Protection.
• Never Reach Over the Blade.
• Use Push Sticks for Narrow Cuts.
• Keep Your Hands Away From the Blade.
• Ensure the Workpiece is Securely Supported.
• Never Force the Workpiece.
• Disconnect the Power When Making Adjustments.
• Inspect the Saw and Table Regularly for Damage.
• Read and Follow the Circular Saw Manufacturer’s Instructions.

Troubleshooting Common Issues

• Vibration: Ensure the circular saw is securely mounted and the table is stable. Add weight to the base if necessary.
• Inaccurate Cuts: Check the fence for squareness and alignment. Ensure the blade is sharp and in good condition.
• Blade Binding: Make sure the riving knife (if present) is properly aligned with the blade. Ensure the workpiece is not pinching the blade.
• Dust Collection Inefficiency: Improve the enclosure around the blade and ensure the dust collector has sufficient suction.

Fathoming Different Fence System

Fence Type	Pros	Cons
Simple Fence	Easy to build, inexpensive.	Requires careful clamping, prone to movement, less accurate.
T-Track Fence	More accurate than a simple fence, adjustable.	Requires T-track installation, can still be subject to slight movement if not properly secured.
Self-Squaring Fence	Highly accurate, automatically aligns to the blade.	More complex to build, requires precise measurements and construction.
Micro-Adjustable	Ability to fine-tune fence position using threaded rods or similar mechanisms for precise cuts, typically used on self-squaring fences	Can add significant complexity to the design and build process, more parts and more careful assembly required to ensure consistent performance

FAQ

• What is the best circular saw to use for a table saw conversion?

  A corded circular saw with a powerful motor and a solid base plate is ideal. Look for a model with a blade diameter of at least 7 1/4 inches.

• Can I use a cordless circular saw for a table saw conversion?

  While possible, cordless circular saws are generally not recommended due to limited battery life and potential power inconsistencies.

• Who is this project suitable for?

  This project is best suited for individuals with some woodworking experience and familiarity with power tools.

• Is it safe to build a table saw from a circular saw?

  Yes, if done correctly and with a strong emphasis on safety. However, a DIY table saw will likely not have all the safety features of a commercially manufactured table saw. Always exercise caution and follow safety guidelines.

• What are some essential safety features to include in my DIY table saw?

  A power switch, push sticks, and potentially a blade guard are crucial. An anti-kickback device is also highly recommended.

• How much will it cost to build a table saw from a circular saw?

  The cost can vary depending on the materials you choose and the complexity of the design. However, you can typically build one for significantly less than the cost of a new table saw. Expect to spend between $50 and $200, excluding the cost of the circular saw itself.

Conclusion

Building a DIY table saw from a circular saw is a rewarding project that can save you money and space. By following these homemade table saw plans and prioritizing safety, you can create a functional and valuable addition to your workshop. Remember to take your time, plan carefully, and always wear appropriate safety gear. Enjoy your new shop-made table saw!