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  • June Project of the Month (Click "x" at right to dismiss)

Shop build beast of a chop saw

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I started this build couple of months ago thinking i'll finish it in a week or two so i continued writing about it in the question & answer section where i had couple of questions, but because is drag on for so long i've decided to move it in the project section.


The first part i had for this build is this very old industrial 10 Hp motor its 3 phase 380v which is standard 3 phase power here in europe, it already had a good size pulley i plan to use in this build.
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Then i bought and gathered all the materials for the table for this project, i bought 80 x 54 x 7 millimeters piece of diamond plate which i plan to use with the smooth side up for the work table of the cut off saw, then i bought couple of square tubing to use for reinforcement, i also managed to clean off the workbench and thru the week when i have time i build the table top with all the reinforcements.
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Couple of days ago i had an hour to spare, so i decided to finish welding the legs to the tabletop, it took little longer than i thought but got it finished and started planning, the pivot point, i have this M24 bolt and nut that should be the perfect size but may end up making a new bolt because of the rust on this one, i'm also debating should i use those 12mm thick triangles or cut the 25mm thick plate and use it instead.
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Tap tap is this thing on?

late last night after finishing some work on the lathe i decided to do some work on this build, next couple of thing i need to make so i can move forward machining related, first of which was to drill two triangles perfectly in the same place without a drill press, so i clean up all the sides with an angle grinder and then i moved the number 3 jaw 2 steps down, wich let me clamp the plates of centre, started with a center drill which broke, then a couple more drill bits broke but managed to drill them straight and did little clean up on the bolt i plan to use, i'm considering should i drill the centre of the bolt for greasing the joint or the barrel, cross drilling a bolt should distribute the grease better, any advice?
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Today i had some time free so i continued machining parts for this saw, started with an thick wall rusty pipe, clean up the end and made an thin pass on the outside.
Then switched to an boring bar and made couple of clean up passes then i cut a bearing seat, then i looked around for an tool for cutting spring clips on the inside and i had non so i made this one by simply welding a piece of HSS to piece of round stock and cut an groove, also repeat the process on the other side and made couple of passes with some sandpaper to clean it for welding.
Then i moved to making the barrel for the hinge to mount the whole assembly to the table simple clean up pass and a hole in the middle.
Then i moved to cleaning and modifying the hinge bolt, it seems to been made by hand because of all the hummer marks, i did a lot of falling with and hand file while it was turning on the lathe to clean it up, also cut the end flat and drill and tap a hole for a grease fitting, there will be a lot of weight on this hinge, the motor alone weights 6-70kg so i'll be greasing the hinge regularly.
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Today i had an hour to spare, so i started on the spindle for this build. After work i went to the steel yard, there wasn't much chose in 32 mm size, so this is 4140 or 4150, machining it it definitely is harder steel then hot rolled, first thing i did is to check it for straightness and is with in 0,10 mm which is not a surprising, because this yard take really good care of it steel. Started by taking one deep cut to get ti close to the bearing size and then cut the rest down to 20 mm then came back and finish the bearing jornal, i did most of the machining with a live centre supporting the workpiece. Then i setup my DIY threading attachment in my tailstock and treated it for M20x1.5, i will be using a double nut setup for safety, more to come.
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Today after work i still had some energy left to do little more machining for this build, first i marked the spindle and chuck up and indicated it. Then i parted it off, cut the side, centre drill it and supported with live centre, then cut it down to 30 mm for the bearing, but made it slip fit and wanted to make it a press fit, so i did little knurling on the bearing side to make it a press fit, now the spindle is finished i need to make an belt pulley which i plan to machine on the spindle itself, more to come.
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Today i had very little time to spare but i did managed to do little machining on the lathe, started with an 60mm small piece of softer steel, it was centre drilled so i started with smaller drill bit and drill it all the way thru and up to 29mm, then used a small boring bar to get it to a tight slip fit with the spindle. Then i relieved one side and cut an o ring groove which i plan to install on both sides to keep the dust out and protect the bearings. i'll fix this pulley blank to the spindle with couple of dal set screws and i'll do the cutting of belt drive grove on the spindle it self. DSC_0111.JPG DSC_0114.JPG DSC_0115.JPG DSC_0118.JPG
Today i found about an hour of free time so i started on the arm that will hold the motor and the spindle, first i measured and marked than i used an angle grinder to cut and form the end to fit over the piece of pipe i machined earlier, the square tubing i used is is 3,5 mm wall and i'll use two pieces in parallel for added stiffness for precision and strength.
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Looks like I'd be to weak to build it , good and stout that's for sure . What size wheels are you planning on using ?? Looks like it could run a 24" diameter abrasive and never even slow down.
I plan to make it to accept 400mm cutting stone, but most common size of stones here is 230mm and 330mm, my ambition is to make it precise and easy to use, ( work horse).
Lately i've been working close to 80 hours a week at work which doesn't leave me much free time to work on my projects but i did managed to get some work done on the arm for this chop saw. I spend some time clamping, tack welding and checking to get the bearing housing 90 degrees to the arm also to keep the two tubes from twisting, welded them at 160a which is the max of my mig, took one brake to let the mig gun cool down. I did check it after it cooled down and is straight, not bad for couple of hours work.
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Today i had some work on the lathe, after i finish it wanted to fix this belt pulley blank on the spindle, first had to chamfer the end, it pushed some material when parting it off. Then i took it in the big garage to place it and drill it for set screws, i plan to run 3 or 6 harden locating set screws but my threading tap fail on the first hole, so i stopped tomorrow i'll get another tap and continued, i'm debating should i cut the v belt grove at 38 degrees or 40 degrees.
Today i continued with threading the holes and fixing the blank to the spindle, i used some super high quality hardened set screws. When i fixed it in place i chucked it up in my lathe, also i supported the other end with a live centre then i first cut 4mm groove close to the bottom. Then i rotated my tailstock and started cutting one side then rotated it again to cut the other side, its not hard just takes time to get both sides same, i used a cheap china grooving insert holder and a fresh sandvik insert.
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