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Forum topic by pete4242 posted 04-16-2014 08:24 AM 1369 views 0 times favorited 13 replies Add to Favorites Watch
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pete4242

20 posts in 301 days


04-16-2014 08:24 AM

Topic tags/keywords: noise dust table saw homemade table saw shop made table saw circular saw circular saw noise circular saw dust circular saw table

Hi,

I finally have decided to attach the circular saw to my work table. I have seen a lot of designs over the internet and I think I know the way to go from here, or at least I have enough information to start on this project.

As I am working in a small room at my apartment, I cant have a lot of sawdust filling the air and would love to keep the noise as low as possible.

I thought of putting together a box under the table to cover completely the saw for two purposes: 1. catching most of the dust. 2. blocking most of the sound waves or at least reducing it to a minimum?? Am I correct with these two assumptions? Any advice to improve on the efficiency of collecting dust and keeping the noise down?
Should I have concerns about the circular saw heating up being in a box?

- pete


13 replies so far

View knotscott's profile

knotscott

5558 posts in 2095 days


#1 posted 04-16-2014 09:16 AM

If you want to keep the noise level as low as possible, find or build yourself a saw with a belt drive induction motor. You’ll only hear the wind noise from the blade….induction motors barely make a hum on their own…..universal motors and circular saws absolutely scream in comparison.


-- Happiness is like wetting your pants...everyone can see it, but only you can feel the warmth....

View lebowtools's profile

lebowtools

1 post in 221 days


#2 posted 04-16-2014 10:01 AM

Totally agree with knotscott here I had a disastrous experience with circular saws, I should recommend to stick with the induction motors

-- Le-Bow Tools - We prefer Quality and Standard! http://www.le-bowtools.com/

View bondogaposis's profile

bondogaposis

2685 posts in 1071 days


#3 posted 04-16-2014 12:12 PM

Yeah, a circular saw makes a lot more noise than a typical belt drive table saw and modern table saws have dust ports for dust collection.

-- Bondo Gaposis

View pete4242's profile

pete4242

20 posts in 301 days


#4 posted 04-16-2014 01:18 PM

Thank you all for the replies – I never knew about the different type of motors used with table saws. That’s one of the advantages of being part of this community here,I really love it.

The difference is clear to me now but going back to my original question, putting the circular saw in a completely closed box would reduce the noise or not much – if anyone has experienced this?

I am not sure about building a table saw with the induction motor… at a first glance, it seems a bit complicated for my mechanical knowledge and skills… I have always wanted to get a bench saw, which I still have it on my “to have” list but seems that I will be facing the same noise problem as apparently they come with universal motor just like circular saws.
The Hybrid table saws on the opposite come with the induction motor and very accurate, as mentioned in some reviews – the main problem is that they are out of my budget. I would pay the price of a bench table saw if it comes with induction motor.

Would you post a link (if you came across any) of homemade table saw with induction motor so I get a clearer idea – I couldn’t find much myself.

Thanks again for your replies

- pete

View knotscott's profile

knotscott

5558 posts in 2095 days


#5 posted 04-16-2014 01:23 PM

I’d be surprised if you couldn’t find an old Homecraft or Craftsman bench saw with a belt drive induction motor similar to the one pictured above for well under $100 (they’re smaller than a standard contractor saw or hybrid saw). I bought one once for $35 just for the motor.

edit….just realized that you’re in Dubai, so my info on used saws probably doesn’t apply.

-- Happiness is like wetting your pants...everyone can see it, but only you can feel the warmth....

View crank49's profile

crank49

3481 posts in 1690 days


#6 posted 04-16-2014 07:48 PM

The box will contain much of the noise if you pad the inside of it.
I have done this with some very loud industrial noises.
The box has to be substantial, like 3/4” MDF or plywood.
The box has to be lined with dense foam rubber; the open cell type.Your saw motor will definitely heat up in the enclosed space, But you can help offset this by piping fresh air to the motor where it normally sucks in cooling air and also pulling hot air, and sawdust out of the box with a vacuum.
The ducts / pipes will also be points of possible noise escape so cover them with foam inside the box as well.
I know all this sounds like a lot of work for something that could be avoided by buying a belt drive saw with an induction motor, but in your situation I suppose that is not an option.

What makes the sound box work is to have a very solid, rigid, and dense outer layer with a soft porous inside layer. Sound waves pass through the foam and hit the hard box and are reflected back inside the box. Then the waves, upon rebound hit the opposite side of the box. Each time, bouncing back and forth the sound level is reduced by the dampening effect of the foam, till the sound does not exist. Dense compressed fiberglass works the same as foam rubber if you don’t have access to foam rubber.

Good luck, and let us know what you did and how it worked.

-- Michael :-{| “If you tell a big enough lie and tell it frequently enough, it will be believed.” ― A H

View Loren's profile

Loren

7808 posts in 2367 days


#7 posted 04-16-2014 07:59 PM

Being in Dubai I don’t expect you’ll have the same sort
of things available we have in N. America.

A box fan could be used to pull more air through the box
to hopefully keep the saw running cooler. A furnace filter
can be used to prevent the fan from expelling the dust.

-- http://lawoodworking.com

View fuigb's profile

fuigb

205 posts in 1677 days


#8 posted 04-16-2014 09:48 PM

Dubai? Pardon the provincialism, but what will you do for raw material?

-- - Crud. Go tell your mother that I need a Band-aid.

View pete4242's profile

pete4242

20 posts in 301 days


#9 posted 04-17-2014 08:32 AM

Thank you all for the replies, the kind of info I was hoping to get and especially from crank49.

I will look into putting together a box made of 3/4’’ plywood padded with 1’’ thick rubber foam (should be enough??). I read somewhere that aluminium foil reflects sound waves – I am thinking of having a layer of that in between the ply and the rubber foam. Your thoughts pls.

How much should the sides of the box move away from the saw, the bigger the box the less heat build up I assume?

- pete

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pete4242

20 posts in 301 days


#10 posted 04-17-2014 08:35 AM

fuigb – well actually I am able to find most of the tools I want for that purpose and wood itself is plenty with a wide varieties – imported obviously!
Otherwise, I will go shopping online… the cost of shipping is most of the times way too expensive, but I guess I have to live with it ;)

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pete4242

20 posts in 301 days


#11 posted 04-29-2014 05:04 PM

I finally found some high density foam – 60KG/cbm open cell. I got it for 40% discount as it is very dirty. I hope it can be cleaned with water. Its a board of 2m x 1m x 25mm thickness. Hope it will do the trick.

I am not sure when I will start this project but I will keep updating this post.

I will add a layer of aluminium foil between the foam and the plywood.

Your thoughts please.

- pete

View peterbb's profile

peterbb

36 posts in 1007 days


#12 posted 04-30-2014 02:30 AM

Mattias Wandel has a couple of articles on making a circuilar saw into a table saw – see http://woodgears.ca/homemade_tablesaw/build1.html

-- Peter

View pete4242's profile

pete4242

20 posts in 301 days


#13 posted 07-22-2014 07:04 PM

Hi,

Been a while since my last post, got busy with some work but did not give up on this project.

Here are some pictures:

the box made of plywood 18mm

with the door attached

and the circular saw attached. All sides are covered with foam from inside except for the top, still to be done

and thats how the whole table looks

I still have to add the miter tracks

and build a fence of course… challenging. I seen some interesting videos on youtube for this purpose. i will update with pictures once done.

The main reason for building this table saw in its current format is to eliminate the noise the saw generates. Well, i was successful at reducing it only, it is like half the noise of a vacuum cleaner now – perfectly acceptable.

I still did not cover the inside of the top, i think it will reduce further the noise. or at least i hope so!
I did not make up my mind still whether I should add the router inside this same table or not. I dont want to add too much weight on the top from inside – to keep it as flat as possible.

Your ideas comments are highly appreciated.

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