DIY Arrow Cut-Off Saw (free components avail. w/purchase)

Basic Description

Here is a little different sort of Dremel-type arrow cut-off saw. First off, I’m using a Dremel knock-off which ran about $19 on ebay. Basically the same thing, but a little longer and louder. You might consider paying $25 more for the real thing.

The Rig with Arrow in Initial Pre-Cutting Position

Now for the blade itself. It does not come as standard (or even add-on) with any Dremel or knock-off rotary unit – you’ve got to build it yourself. More on that further down the page.

The genius of this design is the hinge piece which delivers the arrow into the blade, attributable to my friend, Greg, who is a professional woodworker. I am no woodworking or mechanical guru for sure, so all the credit is due to Greg. The unit is precise, and doubles as a squaring tool. The blade will last a very long time for most folks just cutting their own arrows – this unit is not intended as a professional cut-off saw.

Arrow Delivered to Cutting Wheel via Hinged “L” Holder

As with any cutting of carbon – a known carcinogen – a protective mask should be used if cutting indoors. Since the Chinese made rotary unit is loud, I wear ear protection as well. I also use a clamp (as per photo) to hold the unit securely to the table without vibration, though I’m certain there are multiple ways of accomplishing the same thing. As you can see, I’ve also muffled the sound with felt secured to the rotary device itself, likely not necessary with a real Dremel.

Preparing to Square Up Using Cutting Wheel Face

So far as I can tell, the Roto-Zip 2.5″ carbon based metal cutting wheel (blade) is only available in a package of five, selling for about $10 at Lowe’s. A threaded rod, centering sleeve/spacer-washer, two flat washers, and two hex-nuts must be attached, then epoxied in. The rod, flat washers, and hex-nuts are normally available as singles, but I had to buy a package of 25 sleeves from aluminumspacers.com for about $13; the minimum order. Also, I chose to purchase a package of 15 Hillman 3″ threaded rods from lowes.com for about $12 which I then cut in half rather than cut to length the standard yard long rods offered in stores because those things always have some bend.

Adjustable Nock Stop

For anyone ordering a target panic message, I will ship a cutting wheel assembly – blade, and its (cut to length) threaded rod, washers, centering sleeve/spacer-washer, and hex-nuts with your target panic message on CD at no extra charge. Then all you’ll need to do is epoxy it in (Pic below). You’ll need to send me an email request upon ordering. New orders only.

Any questions will be answered either by email or phone, and yes, I do answer the phone myself (so long as a person’s name is shown on the caller ID).

Parts

1) 1″ x 6″ x 4′ hardwood plank for base
2) 1 Dremel (or facsimilie) multi-speed rotary tool (do NOT buy a battery powered unit)
3) 1 yardstick + 3 1/2″ Phillips screws for fastening it to base
4) 1 Plexiglas shield (removable for easy blade access) 4″ x 6″ + 2 4″ x 5″ slotted plywood holders
5) 1 Common 3 1/2″ door hinge + screws
6) 1 1″ x 1″ x 15″ (approx) hardwood pc. – routed, screwed, or glued into “L” shape (mine is routed)
7) 1 1″ x 2″ x 6″ block of wood for rotary tool platform + screws
8) 1 1/4″ x 15″ threaded rod for specifying arrow length (bent twice at 90 degrees and counter-sunk)
9) 2 1/4″ wingnuts + 6 flat washers and 4 hex-nuts for bent threaded rod
10) 1 2 1/2″ x 5″ length of wood (with drilled hole for threaded rod attachment) as arrow nock stop
Important: drill hole and place wood nock stop on rod BEFORE bending the rod
11) 1 cutting wheel (blade) assembly – the following a, b, c, &d items are what is available free with target panic message purchase. There is no order page option – you must email your request at time of order.
    a) 2 1/2″ Rotary-Zip carbon wheel for cutting metal
    b) 1/8″ x 1 1/2″ threaded rod (4-40 x 3″ as listed on pkg; cut to length)
    c) 6.35mm OD x 3.1mm ID x 2mm length centering sleeve/spacer-washer
    d) 2 ea flat washers and hex-nuts for threaded rod

Freebies

Note: there are a couple of tricks I’ve learned which make it easier to epoxy, as well as allowing for a more precise cutting wheel assembly build. I will include these instructions in any free package of components along with your target panic message on CD.

Optional: 1) table clamp, 2) sound muffling earbuds or phones, 3) face mask, 4) felt or foam vibration limiting material for rotary tool + fastener

My Own Preferred Optional Items