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Rotary Tool Cutoff Saw

by sola_technical, published

Rotary Tool Cutoff Saw by sola_technical Feb 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.

Recent Comments

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1/2" = 12.7mm

Could you post your extension shaft diameter and the hole diameter where it fits? I have the new version of the Dremel shaft extension 225, but as you said it is contoured :(

Can you please upload all of the STLs? I would love to make this.

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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.

Comments

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adrianrv on Aug 24, 2013 said:

Could you post your extension shaft diameter and the hole diameter where it fits? I have the new version of the Dremel shaft extension 225, but as you said it is contoured :(

sola_technical on Aug 24, 2013 said:

1/2" = 12.7mm

Riddellikins on Jul 5, 2013 said:

Can you please upload all of the STLs? I would love to make this.

thecrazy on Oct 5, 2012 said:

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?

sola_technical on Nov 25, 2012 said:

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.

TimKoster on Feb 8, 2012 said:

Awesome! Too bad the 255-01 flex shaft doesn't fit.

elspeth on Feb 8, 2012 said:

Nicely done! :-D

7777773 on Feb 7, 2012 said:

This is fantastic! Thanks!

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