Rotary Tool Cutoff Saw
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Published on February 6, 2012
Description
I designed this to be able to use my Dremel tool & extension shaft as a small cutoff saw. It can cut about 1/4" (6mm) diameter stock in a single cut, or 1/2" (13mm) by turning the stock.
Requires an extension shaft with a 1/2" diameter handpiece; unfortunately, a lot of the extension shafts currently available have contoured handpieces and won't work.
ZIP file contains source files from Solidworks 2011.
Requires an extension shaft with a 1/2" diameter handpiece; unfortunately, a lot of the extension shafts currently available have contoured handpieces and won't work.
ZIP file contains source files from Solidworks 2011.
Instructions
You will also need a 4" (100mm) length of 5/16"(8mm) rod, a 6-32 or M4 screw to hold the handpiece, a 3/8" OD x 1.5" long spring, and a 2"x4"(50mmx100mm) piece of clear plastic for a guard.
Ream the 5/16" hole in the base for a tight fit on the rod, and ream the hole in the arm for a slip fit. Assemble the base and arm with the rod, and put the spring into the spring pockets. Put a 90 degree bend into the guard, and attach the guard to the arm with a small screw. I used 1 screw, so the guard can be rotated off to the side to tighten the cutoff disc to the handpiece. I used 3mm acrylic because I have a bender & lots of scrap; lighter plastic would be ok too.
I would recommend attaching the saw to a sturdy flat base to keep everything from flexing and tipping.
Use 1.25" reinforced cutting discs.
Ream the 5/16" hole in the base for a tight fit on the rod, and ream the hole in the arm for a slip fit. Assemble the base and arm with the rod, and put the spring into the spring pockets. Put a 90 degree bend into the guard, and attach the guard to the arm with a small screw. I used 1 screw, so the guard can be rotated off to the side to tighten the cutoff disc to the handpiece. I used 3mm acrylic because I have a bender & lots of scrap; lighter plastic would be ok too.
I would recommend attaching the saw to a sturdy flat base to keep everything from flexing and tipping.
Use 1.25" reinforced cutting discs.
License
Rotary Tool Cutoff Saw by sola_technical is licensed under the Attribution - Non-Commercial - Share Alike license.
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I love the end of that flex cable attachement. Mine has an ergonomic shape, its hell to design an attachement for. Could you please give us more details about it? Were did you buy it?
Mine is the older version of the Dremel 225. I don't know when the design changed, but the instructions for mine have a rev date of 2000. You can still find the old version on ebay, I'm pretty sure the ones that come in a cardboard box (rather than the blister pack) are the old design.