IN Lately I was very interested in cutting out with a jigsaw, I don’t even know why it would be. It all started with the fact that I needed to cut a few gears out of plywood...
And off we go. At first I sawed the gears by hand, then I thought, pumping a muscle with a manual jigsaw is certainly good, but if you automate the process, it will be much faster!
So, for starters, get acquainted, this is a manual jigsaw for artistic sawing.
(all photos in this article were found on the Internet)
To cut, you need files, they are thin like wire, with sharp teeth. Previously, such files were sold in a pack of 50 pieces. Recently I went to the store, so these "bimesmen" began to sell them individually. During the evening, you can break a couple of pieces of such files.
For sawing, we also need a special table, it can be a board with a conical slot, screwed to the table with screws or a clamp.
For the convenience of attaching files to the machine, it is better to use a special device that 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. In the next photo you see desktop jigsaw factory type, on the Internet you can find a sea of \u200b\u200bdifferent modifications. This thing is not very expensive, but even if I really want it in my city, I can’t find it, and in principle, there’s nothing to it. 
Industrial machines are certainly good, but I will probably use them for a couple of months and abandon this occupation, and in general, such a machine, as I found out, can be easily assembled by myself from plywood and wooden bars.
The next photo uses an industrial manual jigsaw and a spring to return the file.
So, we can easily assemble a desktop jigsaw with our own hands at home. I personally did this, but I have a special design, there are no photos of me in this article, but I will definitely post it, as well as a video in work.
In today's article, we'll look at the extremely interesting homemade, which is sure to come in handy for every DIYer. Namely, today we will look at how to make a jigsaw. This tool is very useful in the household and it very often comes in handy when building any homemade products. Today we will look at one of the cheapest and available options assemblies. Homemade 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 from our Chinese friends. In general, the homemade product is very interesting, so let's not delay with a long preface, let's go!
For this DIY we need:
- Collector electric motor 775 class. (these are usually put on professional RC models).
- Wires
- Some kind of plastic flywheel (large flat gear)
- PVC pipe, the inner diameter of which will be equal to the outer diameter of the electric motor
- Corner for PVC pipes
- Blade for electric jigsaw
- 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
Of the tools we will also need:
- soldering iron
- Solder
- Marker
- Hot glue
- Wire cutters
- Pliers
- Round nose pliers
- Cold welding
- Self-tapping screws
- Screwdriver
- Shrink
- Drill and core drill (diameter equal to the diameter of the engine)
To begin with, we need to choose the most main element design, 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, it should be noted that it is desirable that the motor shaft be on bearings, and not on bushings, as is often the case. We also need some kind of flywheel, the author of the homemade for this took a large and flat gear that he had.
We put our flywheel on the motor shaft, and since the diameter of the inner hole of the flywheel is slightly larger than the diameter of the motor shaft, the author of the homemade product decided to strengthen the connection with a small piece cold welding. Such a connection turned out to be quite strong and reliable. Then, using a simple soldering iron, we solder two 15 cm wires to the contacts of the electric motor and insulate the connection with heat shrink.
After that, we need to take a PVC pipe, the inner diameter of which will be equal to the outer 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 suitable PVC corner for this pipe.
To begin with, we need to make all the necessary holes in PVC pipes. Namely, on a long pipe, we should make a hole for the button. To do this, leave a mark with a marker in a place convenient for you and make a through hole for installing the button. And on 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, which was prepared earlier. Note that the engine must be installed so that there is a minimum clearance between the PVC pipe and the flywheel (but the flywheel itself must not touch the pipe).
For the next step, we need to take the jigsaw blade (which you plan to use) and a small metal plate. We apply the canvas to the metal plate, as shown below, and circle it around the office with a marker. Then, with the help of wire cutters, we cut out triangles from the metal plate so that, as a result, we have antennae in the place where the canvas expands.
We apply the canvas to the plate in the same way as we applied it earlier, and with the help of round-nose pliers we bend and press the antennae first, and then we bend the plate, as shown below. Next, with round-nose pliers, we twist the same “roll” as in the photo (see photo).
The next step we again need to take a small metal plate. We bend this plate with the help of 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 that, we take a not large, but wide board with dimensions approximately as in the photo below. Then, in the indicated place (see photo), using a core drill, we make through hole such a diameter that a PVC pipe with an electric motor sits 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 attach the “T” shaped part to the plate, which is already on the board and, having drilled holes, fasten these plates to the board with self-tapping screws.
Then we need to take a thick and rigid 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 similar to the one shown in the photo below.
After that, 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 horses of the "rod" into the flywheel hole. Rotating by hand, the flywheel checks the operability of the mechanism.
Let's move on to the electronic part of the homemade product. Namely, we set the button. We solder one wire from the electric motor to the button, and the second wire is just a segment of 5-6 cm. We insert the button into its mounting hole and fix it with hot glue. Then, having inserted the wires through the corner, we will install the corner itself on plastic pipe, as shown below.
Then we need to 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 pushed through the mounting hole for the connector), and finally, install and fix the power connector in its place with hot glue.
To the second end of the corner we insert a segment of the same PVC pipe. The length of the pipe should be such that when we put the structure on the table, the handle itself should be exactly parallel to the table. After that, we need to take some small sheet of laminated MDF panels or plywood, the main thing is that it slides well over the surface. From the panel you took, we cut out a similar blank, which is in the photo below and connect it to our mechanism with hot glue, and in the place where it connects to the tree, we fix it with self-tapping screws.
All is ready! As a result, we got very useful tool which will definitely come in handy in your household! It remains to connect the power supply and test, you can see the homemade test below.
Using a desktop jigsaw at home, you can make furniture, beautiful patterned shelves and much more. The mechanism allows you to cut smooth and sinuous parts from wood, plastic and dense foam materials. In order for a home-made device to fully meet the requirements, it is necessary to carefully select the appropriate design.
Design and specifications
The device of any model of an electric jigsaw machine must contain:
- saw;
- crank assembly;
- drive unit;
- saw tension device;
- Desktop;
- auxiliary mechanisms.
The processed material keeps within on a desktop. Some models are equipped with a rotary device that changes the slope of the surface. To make it easier to mark the material with your own hands, graduation is applied to the surface.
How larger size table, the longer the cut can be made. On average, this figure is 30 - 40 cm.
The drive power for a homemade desktop machine is about 150 watts.
The crank assembly converts the rotational movement of the drive into reciprocating and transfers it to the saw. On average, the oscillation frequency of the file per minute is 800 - 1000. The vertical movement amplitude is not more than 5 cm. Some models allow you to select the movement speed depending on the properties of the material.
file manual jigsaw can work with wood, plastic no more than 10 cm thick, having a length of up to 35 cm. For different types materials and works of the file vary, their width is 2 - 10 mm.
The manual tension device secures the saw blade for uniform sawing, it is a helical or leaf spring.
Types of machines
Structurally, all jigsaw devices can be divided:
- with bottom caliper;
- with double support;
- on suspension;
- with degree scale and stops;
- universal.
The most common are models with a lower caliper. Their bed is divided into two halves: lower and upper. At the top there is a cutting and cleaning module. At the bottom there is a control module, an electric motor, a transmission mechanism and a toggle switch. Allows you to process sheets of material of any size.
Double caliper models differ in that there is an additional rail on the upper half of the bed. Such devices are good for creating oversized parts. They are easier to install than the previous version. Both models allow you to process material no thicker than 8 cm. A working table with angle and height adjustment is attached to the machine.
Suspension machines are not equipped with a monolithic bed, they are very mobile. During processing, the cutting module moves, not the material. The working module is usually attached to the ceiling with its own hands, so the size of the material is unlimited. Cutting tool moves manually independently of the bed, creating very complex patterns.
Machines with a degree scale and stops are good for precise work on drawings. The design allows you to avoid errors. Universal jigsaws can perform several operations associated with cutting: drilling, polishing, grinding.
Making a machine with your own hands
Drawing homemade desktop jigsaw: 1 - rocker insert (2 pcs.), 2 - earring (2 pcs.), 3 - table, 4.6 - screws, 5 - thrust, 7 - eccentric, 8 - base, 9 - axes of earrings, 10 - upper rocker , 11 - axis of the rocker, 12 - lamb, 13 - cross member of the tension screw (2 pcs), 14 - tension screw, 15 - rocking stand, 16 - lower rocker, 17 - box, 18 - two-strand pulley, 19 - intermediate shaft, 20 - rack bushing, 21 - table plate, 22 - bearing with cover (2 pcs.), 23 - electric motor pulley.
In the drawing of a do-it-yourself desktop machine, the number of nodes must be minimized, these are: a rocking chair with a fixed saw, a frame and an electric motor. You can take the engine from an old electric machine.
Owners of a manual jigsaw were more fortunate. From a sheet of plywood, you can make a stand and attach a jigsaw to it. To fix the jigsaw with your own hands, you will have to make holes in the base of the tool. The most simple model ready.
Now about more complex and functional ones. The do-it-yourself bed is made of 12 mm plywood, thick plastic or textolite. It is a base, a box for placing the engine and mechanisms, and a work table. On the other hand, we have a rocking chair with an eccentric. They are interconnected by a metal plate with bushing bearings. The whole structure is fastened with screws. To mount the intermediate shaft, prepare a pair of bearings. The two-strand metal pulley is mounted on the shaft as tightly as possible, the screw connection is fixed. In the same way, you can make an eccentric.
To change the amplitude of the movement of the rocking chair, four round through holes with threads are made on the eccentric flange, remote from the axis at different distances. By changing the installation location of the screw, the swing of the rocking chair is adjusted. It is a pair of wooden yokes hinged to a rack. The rear ends of the rocker arms contain through cuts, tension screws are inserted into them. A file is fixed to the ends in front, movable due to metal hinges. Before fastening, the file is inserted into the groove working surface table.
The saw blade attachment mechanism is very important. In the manufacture homemade device with his own hands he should be given Special attention. The insert plates of the rocker arms carry constant loads during movement, therefore they are rigidly fixed and tightened with screws and Grover washers. The fastening earrings should not be strongly compressed by the screws, allowing the hinge axis of the plate to move.
Many people know from childhood the fun of sawing with a jigsaw. The technology is simple. But despite the seeming ease and simplicity of work, you can get very beautiful lace made of wood or plastic. This is a very slow process that requires perseverance and patience. To facilitate labor, jigsaw machines were developed. They are functionally divided into two groups: with manual and electric drive.
Muscle-driven jigsaw device
Homemade machine is easy to make. You can find many drawings of this plywood product. With a jigsaw, with your own hands and with an improvised tool, a simple but functional device is assembled in a short time.
The scope of jigsaws is extensive. They are used for cutting figured products from a variety of materials. And also machines are needed when cutting lumber. In this case, the outer contour of the workpiece remains intact. If you use different nail files, then homemade jigsaw perfectly handle natural wood, plywood, chipboard, plastic, metal, in particular aluminum.
Examples of drawings of a do-it-yourself jigsaw machine, which works on muscle strength, have been repeatedly cited in various magazines of the Soviet era.
Nail files for such a jigsaw machine are produced in the form of a flat blade.
The main parts of the machine:
- Stanina (A).
- A working table with a slot for a saw (B).
- Large drive pulley acting as a flywheel (D).
- Small drive pulley. The drive is combined with a crank mechanism (D).
- Levers (B).
- A pedal that spins the flywheel through the crank assembly (E).
- Saw Tension Unit (G).
The master, constantly pressing the pedal with his foot, spins the flywheel. Through the belt, the movement of the flywheel is transmitted to the second pulley. Which, in turn, makes the crank mechanism with the saw blade move.
If the flywheel is correctly balanced, without distortions and with a uniform, correctly selected mass, then the nail file achieves good smoothness. Such a plywood sawing machine allows you to quickly produce many simple similar products. Cutting time and effort is significantly reduced.
With this design of the machine, the size of the initial workpiece is limited. It depends on the length of the levers (B). When the pattern becomes more complex, it is necessary to rotate the product around the saw.
Since the foot drive does not provide a completely uniform stroke and limits the freedom and imagination of the master, most often such machines are replaced with electric ones.
The design of the electric jigsaw
Electric jigsaw tape - this is a household universal fixture for the manufacture of souvenir products, furniture, various interior items. There are many options for the manufacture of such machines. But the main elements on which product quality and ease of use depend are the electric motor and the blade of the blade.
Main structural elements:
- Saw blade.
- Crank mechanism.
- Drive part.
- Tape tensioner.
- Bed or desktop.
- Various accessories.
Device and principle of operation
Alteration from a manual jigsaw
The first step is to make a desktop for the mechanism. Suitable for these purposes a metal sheet or thick plywood. Holes are drilled and cut out in the worksheet for the cutting tape and fasteners.
Then the jigsaw table is placed on regular table. After fixing, you can assemble the guide rails. To reduce vibration, just cut the rubber gasket right size and put between jigsaw table and main surface.
The above design is convenient in that it can be easily disassembled, and it can be used again as a manual jigsaw.
Since the standard apparatus has springs that tension the saw, a rocker is needed. One end of the rocker arm is attached to the cutting element of the machine, and the other is under spring tension. These simple actions will easily turn ordinary electric jigsaw into the machine.
When using the device, it is important not to forget to turn off the pendulum stroke before starting cutting.
Sewing machine assembly
From a sewing machine, you can also quickly and easily assemble a homemade jigsaw machine. Moreover, this device has interesting feature- the nail file stroke regulator, because on sewing machines There is a speed switch.
First, at the bottom of the machine, you need to find the thread weaving knot. To do this, unscrew a few screws. Inside, the cotter pin is knocked out and the drive shaft is removed, which is connected to the weaving complex. After completing this procedure, the top panel is unscrewed. The groove along which the needle traveled expands slightly to fit the saw blade. The nail files themselves are slightly shortened to the size of the length of the needle. To fix the saw itself, you can make an adapter. But the easiest way is to grind off the upper part of the cutting blade and sharpen the lower one. After that, you can insert the nail file in place of the needle and get to work.
When working with jigsaws of any type, you should not forget about the safety rules. Do not leave the device turned on for a long time unattended.
If the master long hair, then it is better to pick them up or use a special hat. It is better to roll up sleeves on clothes. The room must be well ventilated. In the room where carpentry work takes place, a first aid kit with first aid for cuts must be kept.
A very nimble and compact enough tool, it can be incredibly useful for cutting straight and curly shapes. Appearance and the functionality of the sold jigsaws is impressive, making you 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 a desire to do something with your own hands. It is not necessary to be an expert in technology with years of experience(although this quality will not be superfluous). Next, we will conduct a detailed analysis of the average jigsaw model with drawings, and provide two detailed guides By self-manufacturing similar tool.
How an electric jigsaw works
Although the jigsaw device is not particularly complex, its mechanism has certain features that require familiarization. To understand how to make a jigsaw, you must first understand what makes the saw blade reciprocate. For the most clear idea of the principle of operation of the device, we will present the main components that make up the mechanism of the tool and describe their interaction with each other.At the heart of any electric jigsaw are the following components: an electric motor, a gearbox and a rod with a saw blade clamp. Secondary but no less important elements include the start button, the support roller, the cooling fan and the soleplate. As additional functionality, many models have a pendulum stroke, a dust collector, a backlight and a laser guide. We will not touch on the principle of operation of the latter, and proceed to a description of the interaction of the main elements of the mechanism.
The high-frequency movements of the jigsaw saw blade originate from the electric motor, which is started by pressing a button or directly from the mains. The rotation is transmitted along the shaft to a special “reducer” mechanism with an eccentric, which interacts with the rod, forming reciprocating movements. In the mount, installed at the end of the rod, the saw is fixed, making the cut. To minimize the load on the rod with the gearbox, the rear edge of the saw blade rests against the support roller. Thus, all components of the device are involved in order to perform main task for sawing all kinds of materials.
Drawings of electric balls
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 idea of the principle of operation of the mechanism becomes more visual. Below we have posted a few detailed illustrations, since it is much easier to assemble an electric jigsaw with detailed drawings than to rely only on your own idea of the design features.
We hope that the presented diagrams will completely clarify your understanding of the structure of such a mechanism and give healthy food for reflection 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 great work reproduce it, especially if you have detailed instructions. The bicycle has already been invented, and to make it yourself, it is enough to have a set 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 created product is not a stationary device, but a mobile saw with an electric drive. The power in the device is not so much, but 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)
- Electric jigsaw file with U-shank
- Electric motor RS-540 12V (you can use any similar one)
- Electric circuit closing button
- Nozzle gas stove
- Bicycle spoke
- Plastic circle with a diameter of 260 mm
- Plywood - 120x50x5
- Set of screws, bolts and nuts
- Hacksaw for metal
- triangular file
- Pliers (2 pcs)
- Screwdriver or drill with a set of drills
- Metal shears
- Pencil
The assembly of the jigsaw will begin with sawing out the handle from a larger bar. To do this, it is enough to cut, giving a rectangular board L-shape as in the photo. The dimensions of the sawn part are set "by eye", based on the preferences and size of the operator's hand.
One of the most important nodes a device that serves as a movable rod and a saw blade retainer requires increased reliability. This element is made of a long metal strip, 1 mm thick. At the end, the outline of the file shank is outlined, after which a triangular file is filed 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 an impromptu mount and a through hole is drilled for additional fixation with a bolt.
The saw blade, fixed on the rod, must be connected to the device using a guide. This part is made of rectangular metal plates. With the help of pliers, we bend the center of the plate into a flat groove for the stem with side mounting lugs. To prevent abrasion of wood and facilitate the movement of the file, we apply a similar piece of metal to the front side of the prepared handle and twist it together with the groove. As a result, the following construction should be obtained.
At the end of the rod, carefully bend the metal until a kind of loop is obtained, into which the end of the lever of the crank mechanism will be inserted.
We fasten the previously sawn off wooden rectangle to the top. It will serve as a stand for the motor, creating additional space for mounting the crank elements.
The transformation of engine rotations into reciprocating movements will occur using an elementary mechanism made of a round plate, a gas nozzle and a weight-bearing spoke. In the center of the circle, we 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 with epoxy resin. We put the dried structure on the motor shaft. If the nozzle hole is too narrow, you can expand it with a drill of the required diameter. Between the center and the edge of the circle, we drill another small hole with the diameter of a bicycle spoke.
Unfortunately, not everywhere you can find an upgraded gas stove nozzle with a side screw used in the instructions. If only an ordinary one is available, it can be fixed on the shaft with a tin and a soldering iron, as in the photo below.
Having combined the engine with a round plate, it's time to turn it into a real crank. To do this, we take a bicycle knitting needle and bite off the bent hat and the threaded part with pliers to get an even metal rod. Next, we retreat from one end 10 mm, and bend at an angle of 90 °. We insert the bent part into the previously prepared eyelet in the stem and lift it up so that the screw for fixing the file rests against the metal plate.
The accuracy of the next step is most important, since the amplitude of the movement of the saw blade depends on it. It is necessary to determine the exact place for making the second bend of the rod so that the crank and rod connected by it work most efficiently. To do this, we put the engine in place of the future mounting and place the extreme hole of the circle up. Next, we bring a rod to the hole, the opposite edge of which is inserted into the eye of the rod raised to the stop and mark the place of the bend. We make a bend at an angle of 90 °, insert it into the hole of the circle and check the operation of the mechanism. If the crank works as it should, fix the motor in place with a metal plate.
The next structural element will be the sole, which also acts as a support for the saw blade. You can make a similar part 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 with a self-tapping screw with a countersunk head.
The final step is to install the start button and connect the wires. The button can be displayed in any place convenient for you. The author considered it necessary to put it on hot glue in the corner of the handle. We create an elementary electrical circuit(motor-button-network and motor-network) and connect to a 12 volt power supply.
For smoother running, it is recommended to lubricate the stem with oil.
A more visual demonstration of this instruction, but unfortunately without comments, can be viewed in the video below.
Homemade jigsaw for polystyrene
Assembly of a fairly convenient and reliable device for cutting thin wooden blanks and polystyrene. This method is almost similar to the previous one, but has a more functional design. Compose detailed description how to make this electric jigsaw with your own hands is not necessary, 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) at 12 volts
- A piece of thin, flexible plastic
- Mounting 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:
- File (file)
- Metal shears
- pliers
- Drill or screwdriver with a set of drill bits
- Core drill for wood with a diameter of 44 mm
- soldering iron
- Thermal gun
Also, there is another option homemade jigsaw. The principle of operation 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 for creating your instrument.
Save this page to your social media. network and return to it at a convenient time.
