Chain Saw Sharpener conversion to Hobby Chop Saw

As far as tools go the Chicago Electric  Chain Saw Sharpener is not a great tool for it’s intended purpose.  The motor is week, the arbor and nut are plastic, there is no shaft lock to hold the arbor still while you change disk, and so on. That said it seemed to me that it would make a good hobby chop saw for cutting really small stuff like brass rod, axles, piano wire, push rods and the like. Also the price is right at $29.99 for a good hack.

The big thing holding this saw back is the angle. As it was made to do just one job, they built in a fixed angle for sharpening.  I felt that could be over come. There are some other things will need to change too. The chain advancing handle would not be needed, the blade is not right and a proper vise for holding the material to be cut. So lets look at these one by one. The handle and advancing mechanism can just be removed.  We have to remove the red handle to remove the “bake handle” but it’s just a few screws.

With that out of the way we can look at the disk. They make some very thin wheels 3/64″ that have the same 7/8″ arbor. They are 4.5″ and not the 4″ that comes on it. But with a little trimming on the disk cover they will fit. They are much thinner so we will need a washer or two to make up the thickness so the arbor nut (plastic) will properly engage and tighten. Again there is no “lock” so getting a tight grip on the arbor and the arbor nut is not as easy as it should be. I don’t see an easy way to solve for this without replacing the arbor.

Next we need a good working small vice that will stand up to the parts getting hot. This simple $9 job from amazon should do.

Now to fix that angle problem. Remove the C-clip, hinge pin, and spring. Set those carefully aside for use later. Using a square to keep the 90deg angle, cut the base between 57 and 58 mm up from the bottom. Clean up the cut edges so you have the four empty holes. 3D print the replacement insert. STL print file. Use the printed part to mark a hole for a pin screw on the right back side. Use a 1/16″ drill to drill the hole. Carefully work the 3D part into the base. This is a tight fit and meant to be. We don’t want this coming out later. Put in a #4 or #6 – 1/2″ or 3/4″ screw into the hole to lock the the part in place. Re-attache the motor and disk to the base using the pin, spring, and C-clip. Refer to the image gallery bellow to follow these steps.

You should now have a good little saw for small hobby cutting. Have fun and hobby on.