Scroll Saw From Plywood and Jigsaw

I have always wanted a scroll saw for some smaller projects, but a decent sized one is pretty expensive. That's why I made my own from a cheap jigsaw and piece of plywood. I literally put $25 into this. The plywood was scrap, and the hardware was just laying around. The Jigsaw and blades were the only expenses for me.

Materials:

Plywood(I used a 3'x3'x1/2" scrap piece)

Jigsaw (I used the cheapest thing at Walmart. Considering the price, this one is really good)

Jigsaw Blades (any will work, but I used these because metal blades cut plastic better, which I will use this for)

30x 1" wood screws (I had these laying around, but these are the same thing)

4x 1/4" bolts and nuts

Tools:

Hacksaw

File

Drill

phillips drill driver

1/16" drill bit

1/4" drill bit

1/2" drill bit

Allen Key(Optional, pick the size needed to adjust the jigsaws base plate. Many come with one)

Marker

Tape measure

square(Optional)

Sandpaper (Optional)

Sawhorses (optional, you just need a stable place to cut)

Using a tape measure, mark the above pattern on your wood. You will need:

1x | 18"x18" (top)

8x | 2"x18" (legs and leg braces)

1x | 6"x6" (Saw mount)

4x | 1/2"x2"(tool locks)

Set up your wood on a sawhorse(Or other stable spot), and use your jigsaw to start cutting. I recommend cutting the excess off first so you have less material to work with. Then cut out the pieces for the table. When your done, do a few quick measurements to make sure that the pieces are uniform. If they are a little off, its not a big deal as this doesn't have to be perfect. If you want do a little sanding for a cleaner edge as well.

This step can be done a few different ways, but the goal is the same. You need a 6"x6" hole in the middle for the saw to sit. I used a wood square lined up with a tape measure to get a 6" square. Since this is an 18"x18" table, if you measure 6" on every side, you will get a 6" square in the middle. See the image to get an idea.

Next, take your 1/2" drill bit and drill out the corners so you can make the turn with the saw. Be sure to drill the holes just inside the corners so you won't lose your measurements. Next, just cut out the square one line at a time with the jigsaw. If your measurements are a little small, either sand the edges down, or cut out another line.

Align the legs on top of the table, and mark two dots for screw holes on each piece. Don't draw the dots too close to the edge, or you will crack the wood. Drill out those holes with a 1/16" drill bit. Put the driver bit on your drill, and screw in the screw so it is just poking out of the top. Next, align the leg and screw it all the way in. The second hole should be aligned with the first one now, so go ahead and screw in that one as well.

Do this for all 4 legs. At this point, the legs are very fragile, so don't bend them.

After screwing in the legs, align a brace at the bottom of a leg and mark 2 spots for screw holes. Drill those out with the 1/16" bit, and align the brace about halfway up the leg. put the drill bit through the leg, and mark the first hole with the bit. Take away the brace, and drill all the way through, following the drill bit mark. Screw in the first screw for some support, and then drill the rest holes for the brace and screw in those screws.

Do this for all 4 braces.

Flip your table over and roughly center a 1/16" hole on each of the center hole's sides. Then drill a 1/16" hole on the end of all 4 of the 1/2"x2" tool locks. Insert the screw so it is poking out of the end, align it with the table's holes, and screw them in. Don't over tighten these as you don't want them to go through the table's top, and you want to be able to move them to get the saw in and out.

Congrats, your saw table is done!

Using an allen key, unscrew the jigsaw's base using the angle adjusting bolts. After completely removing the base plate, make sure it will fit on a 6"x6" square, and mark 4 holes in the corners. Using a standard 1/4" drill bit, drill out those holes. Make sure your 1/4" bolts will fit.

Next, align the jigsaw base on the wood base and drill the bolt holes into the wood. Remove the jigsaw base from the wood base, and put a 1/2" bit on the drill. Flip over the wood base and drill about HALFWAY through the wood, following the 1/4" holes.

Next, insert your bolts through the jigsaw and wood bases, and mark the woodline on the bolts. Take them out, and use the hacksaw to cut that line. After cutting, file the edge, and test the threads with a nut. If it screws freely, re-insert the bolts into the bases, press a nut in the 1/2" hole, and tighten everything down. The top of the bolts should be flush with the top of the wood.

Check that everything is tight and flush, and then mark the hole for the blade. I found that a 1/2" hole was big enough, but you may need to go bigger.

The last step is to re-mount the jigsaw to the base. I had to drill 2 small 1/16" holes in the base for the allen key to go through, but you may be able to do tighten the bolts from the sides. Make sure that jigsaw isn't mounted at an angle, as that will show in your cuts.

You're almost done! All that's left to do is mount the saw to the table. Flip the tool locks in, and slide the saw up through the hole. Twist the tool locks back out, and make sure everything is stable. Next, plug in your jigsaw, and turn it on. Mine has a power lock switch, which is great for this application. If yours doesn't have one, just lock the switch on somehow. I would just zip-tie it. This is like a cross between a table saw and a scroll saw, so keep your fingers away from the blade!

Use a piece of scrap wood to test the saw. Slowly push it toward the blade, and hold it firmly. If that was successful, try cutting out a more complicated pattern. This is a great tool to have around, and you will be seeing it in future projects.

Good luck, and happy scroll saw making!

The only reason I made the jigsaw removable is because in the future, I want to make this a modular table. Some of my ideas for attachments are a drum sander, and maybe circular saw. I will link those here if I decide to do that. Thanks!