The article will primarily be useful to those people who often work with wood as a hobby, without making money from it. The author presents a fairly budget-friendly project for a desktop jigsaw, which can be assembled in one day, with minimal costs for materials.
To create the machine you will need the following materials:
- Worker manual jigsaw;
- Plywood;
- Self-tapping screws and bolts with nuts;
- Guides for furniture drawers;
- Two bearings;
- Compression spring;
- Spray paint;
- Self-adhesive paper.
Materials and tools are standard, available in every workshop.
Step 1. Body.
The first step is to create a body for a manual jigsaw from plywood. Here you need to think in advance where the holes for the switch and speed controller will be located.
It should look something like this:
Step 2. Tabletop.
It is better to take a thick piece of chipboard with good coverage, since the workpieces being processed will rub against it during operation of the machine.
A hole for a saw blade is drilled in the chipboard. The jigsaw itself will be attached to the back of the tabletop.
A stem for attaching the boom is also made from furniture guides:
Here's what it looks like assembled:
And the tabletop is attached to the body:
Step 3. Arrow.
The boom itself will be made of two furniture guides. They are bolted together to increase rigidity.
The boom supports are made of chipboard. Before painting and installing them, the point at which the boom is attached to the support is measured. Before doing this, they need to be installed in their place:
After this, it is necessary to drill holes in the support for the bearing seats.
Step 4. Painting.
The prepared supports are spray painted.
While they dry, the machine itself is covered with self-adhesive tape.
Step 5. Assembly.
Bearings are inserted into the supports and screwed into place.
The boom mounting axis will be made of two bolts screwed into the guides as shown in the photo. The diameter of the bolts is selected in accordance with the diameter of the inner race of the bearing.
The bolts are tightened securely, after which the two halves are screwed to each other.
This clearly shows how the boom will be secured in the supports:
The boom is installed in its place and secured with nuts.
Next you need to install the garter spring. It is necessary in order to return the arrow to its original position after the jigsaw pulls it down. This is how the saw will move back and forth. It must be adjusted so that it is not too soft (this will complicate the operation of the machine) and too hard (this can lead to overheating of the jigsaw motor).
How to secure it is shown in the photo:
Then, from a thin strip of metal (1 mm), it is necessary to make fastenings for the file to the arrow. They must rotate freely on the axis, since during operation the boom changes its angle of inclination to the jigsaw, and if they are static, this can lead to breakage of the saw.
This is what the mounts should look like:
The boom supports are additionally reinforced with a long bolt, it can be seen in the photo:
Step 6. Electronic part.
Since access to a manual jigsaw is limited, it is necessary to place the controls on the outside of the body.
To adjust the rotation speed of the jigsaw electric motor, the author used a phase power regulator. Here is its electrical diagram.
Lately I have been very interested in cutting out with a jigsaw, I don’t even know why. It all started with the fact that I needed to cut out several gears from plywood...
And off we go. At first I cut out the gears by hand, then I thought, pumping the muscle with a hand jigsaw is of course good, but if you automate the process, it will be much faster!
So, first of all, let's get to know this manual jigsaw for artistic cutting.
(all photos in this article were found on the Internet)
To saw you need files, they are thin as wire, with sharp teeth. Previously, such files were sold in a pack of 50 pieces, recently I went to the store, and these “bimesmen” started selling them individually. You can break a couple of these files in an evening.
For cutting, we will also need a special table, it can be a board with a conical slot, screwed to the table with screws or a clamp.
To make it easier to attach saw blades to the machine, it is better to use special device, which will compress the contour of the jigsaw, so you can easily change the file without effort. With the help of a wooden eccentric, compression occurs.
And now about automation. On next photo you see table jigsaw factory type, you can find a sea of different modifications on the Internet. This thing is not very expensive, but even if I really want it, I won’t be able to find it in my city, and in principle there’s no need. 
Industrial machines are, of course, good, but I’ll probably use them for a couple of months and give up on this activity, and in general, such a machine, as I learned, can be easily assembled yourself from plywood and wooden blocks.
The following photo uses an industrial manual jigsaw and a spring to return the saw.
So, we can easily assemble a tabletop jigsaw with our own hands at home. I personally did just that, but I have a special design, there are no photos of me in this article, but I will definitely post them, as well as a video in progress.
A very fast and fairly compact tool, it can be incredibly useful for making straight and curved cuts. Appearance and the functionality of the jigsaws sold are impressive, making one believe in the incredible complexity of the design of these devices. In fact, to recreate such a mechanism, it is enough to understand the principle of its operation, have instructions and the desire to do something with your own hands. It is not at all necessary to be an expert in technology with many years of experience (although this quality will not be superfluous). Next we will carry out detailed analysis average jigsaw model with drawings, and we will provide two detailed manuals on self-production similar tool.
How does an electric jigsaw work?
Although the device of a jigsaw is not particularly complicated, its mechanism is certain features, requiring familiarization. To understand how to make a jigsaw, you first need to understand what causes the saw blade to make reciprocating movements. For the clearest understanding of the principle of operation of the device, we will present the main components that make up the mechanism of the instrument and describe their interaction with each other.The basis of any electric jigsaw is the following components: an electric motor, a gearbox and a rod with a saw blade clamp. To the secondary ones, but no less important elements, include the start button, support roller, cooling fan and soleplate. As additional functionality, many models have a pendulum stroke, a dust collector, lighting and a laser guide. We will not touch upon the operating principle of the latter, and will move on to a description of the interaction of the main elements of the mechanism.
The high-frequency movements of the jigsaw saw blade originate from an electric motor, started by pressing a button or directly from the network. Rotation is transmitted along the shaft to a special “gearbox” mechanism with an eccentric, which interacts with the rod, forming a reciprocating movement. The mount installed at the end of the rod holds the saw that makes the cut. To minimize the load on the rod with the gearbox, the rear edge of the saw blade rests against the support roller. In this way, all components of the device are involved to perform the main task of sawing all kinds of materials.
Electrobolic drawings
A detailed study of any device is much easier when there is detailed diagram with a description of each element. Thanks to the exact names of parts with dimensions, the general understanding of the principle of operation of the mechanism becomes more clear. Below we have placed several detailed illustrations, since assembling an electric jigsaw with your own hands with detailed drawings is much easier than relying only on your understanding of the design features.
We hope that the presented diagrams will completely clarify your understanding of the structure of such a mechanism and provide useful food for thought in assembling your own jigsaw.
Making a jigsaw with your own hands
For a craftsman who understands the principle of operation of any mechanism, it will not be difficult to reproduce it, especially if he has detailed instructions. The bicycle has already been invented, and to make it yourself, it is enough to have a kit available necessary details and tools. The guide below will demonstrate in detail how to make a jigsaw with a complete listing of the elements and tools required for the job. The product being created is not a stationary device, but a mobile saw with an electric drive. The device has not much power, but it is enough to cut wood up to 5 mm thick.
Required materials:
- Wooden block - 150x75x25 and 75x25x25 (width, height, thickness in mm)
- Metal plates – long and rectangular (as in the photo)
- Jigsaw blade with U-shank
- Electric motor RS-540 12V (any similar one can be used)
- Circuit closing button
- Nozzle gas stove
- Bicycle spoke
- Plastic circle with a diameter of 260 mm
- Plywood - 120x50x5
- Set of self-tapping screws, bolts and nuts
- Hacksaw for metal
- Triangular file
- Pliers (2 pcs)
- Screwdriver or drill with a set of drills
- Metal scissors
- Pencil
Assembling the jigsaw will begin by cutting out the handle from a larger block. To do this, it is enough to make a cut, giving the rectangular board L-shape as in the photo. The dimensions of the cut part are set “by eye”, based on the preferences and size of the operator’s hand.
One of the most important components of the device, which serves as a movable rod and a saw blade clamp, requires increased reliability. This element is made of a long metal strip, 1 mm thick. At the end, trace the outline of the file shank, after which a notch is made with a triangular file to create a pressure plate. Part of the metal strip is bent with pliers along the contour of the shank, after which a file is installed in the improvised mount and a through hole is drilled for additional fixation with a bolt.
The saw blade mounted on the rod must be connected to the device using a guide. This part is made of rectangular metal plates. Using pliers, bend the center of the plate into a flat groove for the rod with side mounting lugs. To prevent abrasion of the wood and facilitate the movement of the saw, we apply a similar piece of metal to the front side of the prepared handle and screw it together with the groove. As a result, the following design should be obtained.
At the end of the rod, we carefully bend the metal until we get a kind of loop into which the end of the crank mechanism lever will be inserted.
We screw the previously sawn-off wooden rectangle to the top. It will serve as a stand for the motor, creating additional space for installing crank elements.
The conversion of engine rotations into reciprocating movements will occur using a simple mechanism made of a round plate, a gas nozzle and a weight-bearing spoke. In the center of the circle, drill a hole with a diameter equal to the threaded part of the nozzle (so that it fits as tightly as possible). Next, install the nozzle in place and fix it using epoxy resin. We put the dried structure on the electric motor shaft. If the nozzle hole is too narrow, you can widen it with a drill of the required diameter. Between the center and edge of the circle, drill another small hole with the diameter of a bicycle spoke.
Unfortunately, it is not possible to find the upgraded gas stove nozzle with a side screw used in the instructions everywhere. If only an ordinary one is available, it can be fixed on the shaft using tin and a soldering iron, as in the photo below.
Having combined the motor with the round plate, it's time to turn it into a real crank. To do this, take a bicycle spoke and use pliers to bite off the curved head and threaded part to form an even metal rod. Next, we retreat 10 mm from one end and bend it at an angle of 90°. We insert the bent part into the previously prepared eye in the rod and lift it up so that the saw fastening screw rests against the metal plate.
The accuracy of the next step is most important, since the amplitude of movement of the saw depends on it. It is necessary to determine the exact location for the second bend of the rod so that the crank and rod connected by it work most efficiently. To do this, we place the engine in the place of the future mounting and place the outermost hole of the circle upward. Next, we bring a rod to the hole, the opposite edge of which is inserted into the eye of the rod raised all the way and mark the place of the bend. We bend it at an angle of 90°, insert it into the hole of the circle and check the functionality of the mechanism. If the crank works as it should, fix the motor in place using a metal plate.
The next structural element will be the installation of a sole, which will also serve as a support for the saw blade. A similar part can be made from ordinary plywood, 5 mm thick. In the center of one of the ends, we make a small cut (20-30 mm) and pass the file of our jigsaw into it. We fix it with a self-tapping screw with a countersunk head.
The final stage will be installing the start button and connecting the wires. The button can be displayed in any place convenient for you. The author considered it necessary to place it on hot glue in the corner of the handle. Creating an elementary electrical circuit(motor-button-network and motor-network) and connect to a 12-volt power supply.
For more smooth running, it is recommended to lubricate the rod with oil.
A more visual demonstration of this instruction, but unfortunately without comments, can be seen in the video below.
Homemade jigsaw for polystyrene
Assembling a fairly convenient and reliable device for cutting thin pieces of wood and polystyrene. This method almost similar to the previous one, but has a more functional design. Compose detailed description how to do this electric jigsaw do it yourself, there is no need, since the design of the device is similar to the previous assembly. We will bring full list necessary materials and manufacturing tools.
- Plywood 200x200x5 mm
- Wooden block - 120x50x50
- Spatula or sheet of metal, 1 mm thick
- Metal terminal for connecting wires
- Metal rod (spoke)
- Hacksaw blade
- Electric motor (DC) 12 volt
- A piece of thin, flexible plastic
- Fastening metal corner
- A piece of PVC pipe as a handle
- Contact closure button
- 12 volt power supply with DC plug
- DC power connector
- Self-tapping screws, bolts and nuts
By instruments:
- Needle file
- Metal scissors
- Pliers
- Drill or screwdriver with a set of drills
- Core drill for wood with a diameter of 44 mm
- Soldering iron
- Thermal gun
Also, there is another manufacturing option homemade jigsaw. The operating principle of this product is similar to the previous two; there are some nuances in the design. We hope that the following video will be useful and give you fresh ideas to create your own instrument.
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In today's article we will look at extremely interesting homemade product, which will surely come in handy for every DIYer. Namely, today we will look at how to make a jigsaw. This tool very useful in the household and it itself very often comes in handy when building any homemade products. Today we will look at one of the cheapest and available options assemblies. The homemade product will consist of the cheapest and most available materials, which you probably have at home, and if not, then you can easily find them in your city, or you can order them from our Chinese friends. In general, the homemade product is very interesting, so let’s not delay with a long introduction, let’s go!
For this homemade product we will need:
- 775 class commutator motor. (these are usually installed on professional RC models).
- Wires
- Some kind of plastic flywheel (large flat gear)
- PVC pipe, the internal diameter of which will be equal to the external diameter of the electric motor
- Corner for PVC pipes
- Jigsaw blade
- Small metal plate
- A small (but thick) board
- Thick wire (or, for example, a bicycle spoke)
- Button
- Power connector
- Power supply (12-24v 1-2A)
- Not a large sheet of laminated MDF panel or plywood
We will also need the following tools:
- Soldering iron
- Solder
- Marker
- Hot-melt adhesive
- Wire cutters
- Pliers
- Round nose pliers
- Cold welding
- Self-tapping screws
- Screwdriver
- Heat shrink
- Drill and core drill (with a diameter equal to the diameter of the engine)
First, we need to select the most important structural element, namely the electric motor. In our case, it should be with a large number of turns (such an engine has a large torque). And also, in order for the homemade product to serve you for a long time, you should take into account that it is desirable that the electric motor shaft rests on bearings, and not on bushings, as is often the case. We also need some kind of flywheel; for this, the author of the homemade product took a large and flat gear that he had.
We put our flywheel on the electric motor shaft, and since the diameter of the internal hole of the flywheel is slightly larger than the diameter of the electric motor shaft, the author of the homemade product decided to strengthen the connection with a small piece cold welding. This connection turned out to be quite strong and reliable. Then, using a simple soldering iron, we solder two 15cm wires to the contacts of the electric motor and insulate the connection with heat shrink.
After which we will need to take a PVC pipe, the internal diameter of which will be equal to the external diameter of the electric motor. This pipe will serve as both a motor mount for our engine and a handle for our tool. We also need one for this pipe suitable PVC corner.
To begin with, we need to do everything in PVC pipes required holes. Namely, on a long pipe we should make a hole for the button. To do this, use a marker to leave a mark in a place convenient for you and make a through mounting hole for installing the button. And at the corner we should make a hole for installing the power connector (to make a hole, we repeat the same steps as we did with the pipe above).
Then we “press” the electric motor into the PVC pipe that we prepared earlier. Note that the engine must be installed so that there is a minimum gap between the PVC pipe and the flywheel (but the flywheel itself should not touch the pipe).
For the next step we will need to take a jigsaw blade (whichever you plan to use) and a small metal plate. We apply the canvas to the metal plate, as shown below, and trace it around the office using a marker. Then, using wire cutters, we cut out triangles from the metal plate so that we end up with antennae where the blade expands.
We apply the canvas to the plate in the same way as we applied it earlier, and using pliers we bend and press the antennae first, and then bend the plate, as shown below. Next, use round pliers to twist the same “roll” as in the photo (see photo).
The next step we will again need to take a small metal plate. We bend this plate using pliers so that we get a “T” shaped part with a groove inside. Inside the groove itself, the canvas that we previously prepared should move quietly.
After which we will take a small, but wide board with dimensions approximately as in the photo below. Then, in the indicated place (see photo), using a core drill, we make a through hole with such a diameter that a PVC pipe with an electric motor fits securely in it.
We apply another metal plate to the newly made workpiece in the place indicated in the photo. The metal plate should be slightly larger in width and length than the “T” shaped part that was made earlier. Then we apply the “T” shaped part to the plate that is already lying on the board and, having drilled holes, screw these plates to the board using self-tapping screws.
Then we need to take a thick and stiff metal wire or, for example, a bicycle spoke. And from this knitting needle we should make a kind of connecting rod (see photo). This part must connect the blade and the flywheel so that when the flywheel rotates, the blade moves “back and forth.” You should end up with a piece approximately the same as shown in the photo below.
Then we install the “connecting rod” first on the canvas, and then install the PVC pipe with the electric motor in its place (to the board, as in the photo below). And the second “connecting rod” goes into the flywheel hole. By rotating the flywheel by hand, we check the functionality of the mechanism.
Let's move on to the electronic part of the homemade product. Namely, we install the button. We solder one wire from the electric motor to the button, and the second wire is just a 5-6cm piece. We insert the button into its mounting hole and secure it with hot glue. Then, having inserted the wires through the corner, we will install the corner itself on plastic pipe, as it is shown below.
Next we should install the power connector. We solder the wires coming from the electric motor and from the button to the connector itself (the wires should be inserted through the mounting hole for the connector), and finally, we install and secure the power connector in its place using hot glue.
We insert a piece of the same PVC pipe to the second end of the corner. The length of the pipe should be such that when we place the structure on the table, the handle itself should be exactly parallel to the table. After which we will need to take some small sheet of laminated MDF panel or plywood, the main thing is that it glides well over the surface. From the panel we took you, we cut out a similar blank as in the photo below and connect it to our mechanism using hot glue, and in the place where it connects to the wood, we fix it with self-tapping screws.
All is ready! In the end we got very useful tool, which will definitely come in handy for you on the farm! All that remains is to connect the power supply and test it, you can see the homemade test below.
I didn’t want to permanently place my expensive Makita jigsaw on the table, so I decided to buy another one to create a table. I was very lucky to find a jigsaw in the “Our House” store Caliber LEM-610E for only 862r. Includes: wood saw, side stop, adapter for vacuum cleaner, spare brushes for the motor.
There was an outlet next to the display case and I looked at it in action. It is quite well made, convenient, there is a speed control with a wheel, and the activation is fixed with a button. The saw holder moves smoothly without any play.
It’s very fortunate that I was able to twirl it in my hands before buying it; I wouldn’t risk ordering it from the Vseistrumenty.ru website without knowing what it is. (Although they write good reviews about it) By the way, it costs more there and there is also a delivery fee... so I successfully bought it at Our House. :)
Despite its advantages, it has a number of disadvantages that I noticed upon closer examination:
1) The file does not fit into the saw holder. Apparently this is a defective copy, but I did not waste my time on the exchange. Each file has to be sharpened. (Although I won’t be able to use them on the second jigsaw after grinding - it doesn’t matter, they are relatively inexpensive)
2) And this flaw is visible even in the picture. The canvas is tilted strongly forward. (This was also corrected by placing tin strips under the back of the sole, achieving 90 o.
3) The speed control wheel turns heavily, not very clearly and with jamming. At the minimum speed value, the tool cannot start at all (However, the same garbage with the start is also true for my other “calibrated” drills. This is unpleasant, but does not spoil life much)
As always, everything is in the spirit of minimalism. I did not make a separate switch. It is quite convenient to turn on with a standard button and lock into place.
To do this, I bought a bracket at KrepMarket (this is a fastening element from some kind of iron structure system)
By the way, I really love CrepeMarket. Any screws, nuts, screws, fasteners. Every time I design something, I wander around in thought and collect the necessary details.
I cut off the excess and sharpened it.
Back view. Now the distance between the bearings has a fixed clearance for the file of 1.2mm. I have a plan for the future: to make a gap adjustment.
For thin materials it can be lowered.
As an experiment, I drew a star and tried to cut it out evenly
For a 130mm file, the maximum possible thickness is 5cm. It turns out there are very long files; I recently saw a 300mm file on the market
I sawed off a 1.5mm slice from a 40x40mm block
Which is what I did. Now you can use it to cut long workpieces 11.5 cm wide. The old L-shaped structure also remains, and if greater strength of the holder is needed, it can be installed again, although new design remained quite strong and reliable.
I also came up with the idea of making a knife from an old dull file, grinding off its teeth and sharpening it.
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They can be used to cut material like sealant into shapes. The cut is smooth. Much better than a utility knife. The photo shows a mouse pad.
Well, that's probably all. The table turned out to be reliable and comfortable. Now I have a tool with which I can perform more delicate work than with a circular saw.