Dremel - Mini Table Saw.pdf - Dremel(1) - dariziel2

Mini - Table Saw / Router / Shaper

PLANS

for Dremel Rotary Tool

Complete set of easy to use templates with detailed instructions.

Includes material supply and price list.

Table Top Extension plans -

Allows table saw to extend up

to 12” on either side!

Complete set of easy to use templates with detailed instructions.

Includes material supply and price list.

Material Supply / Price List

Description Qty *Price

Total

1x8x4 top choice whitewood board

1x2x4 top choice whitewood board

Optix 8x10 acrylic sheet (.080” thick)

3/4” two hole pipe strap - (bag of 4)

1/4”x 4-1/2” bolts

1/4” wing nuts - (bag of 4)

3/4” foam pipe insulation (sold in 6ft sections)

Wood screw - #6 x 1-1/2” - (bag of 10)

Wood screw - #4 x 5/8” - (bag of 12)

2” Spring Clamp

$4.28

$1.22

$1.98

$0.85

$0.34

$0.98

$0.97

$0.98

$0.99

$4.28

$1.22

$3.96

$0.85

$0.68

$0.98

$0.97

$1.96

$0.98

$1.98

* Tax Not Included

Total

$17.86

Attachments / Accessories / Tools List

Dremel Rotary Tool (templates were designed for model 4000 but can be modiied to it any model)

Dremel - Mini Saw Attachment (model 670)

Dremel - Sanding Drum (either model 407 or 470 will work for this application)

5/32” Drill Bit

5/64” Drill Bit

7/64”Drill Bit

1/4” Drill Bit

Phillips screw driver

Elmers glue

Utility knife (or other razor)

Optional Dremel Attachments/Accessories:

(only needed if you plan to build this project *exclusively with a Dremel Rotary Tool)

Dremel - Plunge Router Attachment (model 335-01) “OR” Multi Purpose Cutting Kit (model 565)

Dremel - Circle Cutter and Straight Edge Guide (model 678-01)

Dremel - Brad Point Drill Bit Set (model 631-01)

*Note: the top plate cover screws require a tapered 1/4” counter sink. The Dremel Brad Bits are not tapered

and Dremel does not currently make a tapered 1/4” drill bit with a 1/8” shank. This will require the need for an

additional drill (preferably drill press) that can handle standard 1/4” drill bits or 1/4” tapered counter sink bits.

Assembly / Directions:

Step One - Cut the wood to proper length:

I suggest when purchasing the supplies, have the hardware store cut the wood for you. This will save time and

assure clean straight cuts. The following are the cuts you will need to make this table.

1x8x4:

2 - 10” in length (table top and back plate)

2 - 4” in length (left and right side panels)

1 - 8” in length (optional table extension)

* Select None for Page Scaling in the printing options!

1x2x4:

4 - 5-1/2” in length (braces and brackets)

2 - 12” in length (optional extension arms)

Step Two - Cutting / Drilling the Table Top and Back Panel:

Once you have all the wood cut to length, *print out the templates and look through them. For best results print

the templates on 100 pound card stock. Be sure to select None for Page Scaling in your printer options!

Starting with the Table Top template you will notice a bold boarder, several faded dashed lines, some drill hole

placements and a bold dashed line that represents the cutout for the Dremel rotary tool and Mini Saw Attach-

ment. There is also a faded solid line that represents the pipe strap that will be mounted underneath the Mini

Saw Attachment between it’s directional guide and coupling (see Mini Saw Attachment operating instructions) .

The faded lines in each template represent items on the opposite side of the viewing perspective (as if the tem-

plate were transparent) . Cut the template along the boarder and also cut along the dashed line for the Dremel

and Mini Saw Attachment.

Select one of the 10” panels (cut from the 1x8x4) to be your table top

and lay the template over it. Secure it with some scotch tape or simply

hold it in place while tracing the outline of the Dremel and Mini Saw

Attachment (1) . Use a punch, nail, or screw to mark the drill holes. Put

an indentation into the wood to help steady the drill bit when you start to

drill the holes.

Clamp the panel down and route out the area you traced using a Dremel

Plunge Router or Dremel Multi Purpose Cutting Kit (follow the instruc-

tions for those tools using appropriate routing techniques) (2) . If you

do not own one of these attachments, then use a jig saw or other means

of cutting the wood. The template was designed so the Dremel tool and

Mini Saw accessory will it snug, so continue working the edges until

they are just able to slide through the top plate.

Once you are inished routing, drill the holes using the appropriate

bits (labeled on the template) . Note that if you are planning to build

this project using only Dremel tools and accessories you will need the

Dremel Brad Point Drill Bit Set for the 5/32” and 1/4” drill holes / coun-

ter sinks.

Here’s a tip - if you don’t have access to a drill press to counter sink the

holes, use the 1/4” drill bit to irst drill into the wood just enough for the

counter sink. Then inish drilling the hole using the smaller drill bit.

Follow the above instructions for the Back Panel. No routing or cutting

is necessary - only drilling.

Step Three - Side Panels:

The side panels are already the size we need for this project. However, you will notice on the template there

is an optional decorative cut line. Feel free to use this if you would like to dress up your project a bit. On the

bottom of the side panel page you will ind what I call a “contour template” . This is for the left side panel only.

The right side will need no additional cutting or shaping.

Cut out around the boarder and along the cut line. Fold along the lines and place the folded template directly

over the top of the LEFT side panel (3) . Make sure the side of the template labeled “ outside ” is on the side you

want to be seen (one side of the wood usually looks nicer than the other). Trace the outline and use the Dremel

to shape the wood until the contour matches “close” to that of the line. DO NOT sand this down too much at

this time! For now just get close to the outline and later you can make for a perfect it.

This contour will brace the body of the Dremel Rotary tool and help hold

it in place. If you own a Dremel or rotary tool other than the model 4000,

you will need to shape this area

to it the contour of your Dremel

model. For the whitewood board

used in this project a sanding

drum will sufice when shaping

the contour (4) . If you wish to use

a harder wood, you may need to

use a different dremel accessory

for this step.

Step Four - Brackets and Braces:

There are two brackets and two braces (for use with rotary tool in vertical position) . The two brackets will

clamp the tool in place while the top and bottom braces will simply keep the tool from moving as you apply

pressure when routing / shaping a work piece (5) . Follow the same procedure for these four pieces as you did

when shaping the rotary tool contour for the left side panel. When drilling the 1/4” holes for the brackets, make

sure they align nicely with the 1/4” holes you drilled in the back panel (6) . You may even want to set them in

place and mark them using the holes in the back panel.

Remember the rule - measure twice, cut once (in this case drill). It is recommended to use a drill press for this

procedure. If you do not have access to a drill press, start by using a small drill bit irst making sure to get good

alignment, then increase the hole in steps until you reach 1/4”.

Step Five - Assembly:

Once all of the pieces are cut, drilled, and shaped, it’s time to put it together.

Using the #6 x 1-1/2” screws, screw the side panels, top brace and bottom brace to the back panel. It is a good

idea to drill pilot holes to keep from splitting the wood (the 5/64” drill bit should work nicely for this) (7) . Be-

fore you can set the Table Top in place you will need to attach the 3/4” pipe strap to the bottom of the Table Top

using two #4 x 5/8” screws. The 5/64” holes have been previously drilled so the center of the strap should line

up very nicely over the cut out for the Dremel Mini Saw Attachment (8) .

When you turn the Table Top over and try to set it in place, you should notice the strap will not allow the top to

sit level. The edge of the strap overlaps the back panel. The easiest solution for this is to use a sanding drum

to groove out a place on the back panel for the edge of the strap to sit into (9) . Now screw the table top in place

and assembly is complete.

Note that if you try and set the Dremel rotary tool and Mini Saw Attachment in place, the Mini Saw Attachment

will not sit level with the Table Top (10) . Cut a 2-1/4” section of foam pipe insulation. Squeeze it together then

bend it so it is shaped as if it is smiling at you (11a) . Place it into the cavity of the Mini Table Saw attachment

turning it so the folded side is down (11b) . Now when you place the Dremel rotary tool and Mini Saw Attach-

ment in place you should have to push it down to hold it level with the Table Top.

Now go back and inish the left side panel contour for your rotary tool. Set the Dremel rotary tool and Mini

Saw Attachment in place (the on/off switch should be facing the front of the table saw and facing slightly down-

ward) . Hold the tool in place making sure the Mini Saw Attachment is level with the table and look to see how

high the rotary tool sits above the table. Using a sanding drum, sand down a little of the side panel contour and

check it again. Continue shaping and contouring the side panel until the rotary tool sits just below the surface

(12) . You will need to repeat this process for the brackets and braces so the rotary tool is centered when in the

vertical position. Remove just enough of the contoured areas of the brackets and braces to glue in place some

foam insulation where the Dremel rotary tool will sit (see image on cover) .

11a

Step Six - Table Saw and Router/Shaper Cover Plates:

When conigured as a mini table saw, the cover is used to hold the rotary tool and Mini Saw Attachment in

place. The acrylic sheets are 8”x10” so they will need to be trimmed down to it the table top. To do this,

11b

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