Power Hacksaw

thingiverse

This saw uses SCS8UU bearings and 8mm steel rods, powered by a 25mm 12v 100rpm geared motor that I already had, so I built this version. The base is made of 295x200x10mm MDF and is currently being printed with the other parts. This design can handle items as large as 50mm square, and the vice shown in the picture measures 4545 x 250mm. To complete the saw, you will need to source additional parts, including two 8mm steel rods (340mm long), two 6mm threaded rods (200mm long), three SCS8UU bearings, a rocker switch with a 19.5 x 13mm hole, a roller switch (KW11 3Z), a hex motor coupler with a 4mm shaft, two hinges measuring 100mm x 72 mm, and a DC 2.1mm panel mount socket. You will also need six millimeter couplers or wingnuts, a four-millimeter by twenty-millimeter threaded spacer or wingnut, and three millimeter bolts (8mm button flanged) for the motor. To assemble the base, you'll require eight four-millimeter nuts and twenty-millimeter long bolts. For the hinges, use sixteen four-millimeter nuts and sixteen-millimeter long countersunk bolts. The steel rods will be secured with two four-millimeter nyloc nuts, twenty-five millimeter long bolts, and two washers. To connect the motor to the blade assembly, you'll need a four-millimeter by twenty-millimeter bolt, a four-millimeter nyloc nut, and two penny washers. Ten four-millimeter washers can be used as bearings (refer to the last picture). The connection between the three SCS bearings and the green board requires a six-millimeter by fifty-millimeter bolt, a six-millimeter washer, and a nyloc flange nut. You'll also need twelve four-millimeter bolts measuring sixteen millimeters long, as well as three four-millimeter bolts measuring twenty-five millimeters long, two four-millimeter bolts measuring thirty-five millimeters long, five four-millimeter half nuts, and three four-millimeter washers. To secure the vice on the board, you'll need three four-millimeter by thirty-five-millimeter bolts, three four-millimeter washers, and three four-millimeter nyloc nuts. For the stud, use four six-millimeter half nuts. If the other vice is used, you'll require additional parts: three four-millimeter by thirty-five-millimeter bolts, three four-millimeter washers, and three four-millimeter nyloc nuts. Recent changes to the design include enlarging the hole on the "motor mount" due to issues with the DC connector threads. The original 3mm x 6mm bolts for the motor interfered with the shaft coupler, so these need to be replaced with 3mm x 8mm (max) button flange bolts. Additional modifications include adding packing pieces to ensure the blade is level or pushing down on the cutting stroke. A new saw base template has been created with holes for this feature. A motor mount and clamp have been designed for a 37mm geared motor, and the drive piece has been modified for more power and slower cuts. A printable hinge has also been made for the saw, requiring a four-millimeter steel rod that is 210 millimeters long. To assist with cutting, additional weight can be attached to the assembly using longer bolts on the "bearing mount."