A fun little project to make a toy for your child or grandchild. Laser-cut a circular saw that actually turns with a crank. No laser cutter? You can also cut the parts with a scroll saw. The toy saw is made from 1/8” or 1/4” birch plywood and is about 9 inches long by 7 inches tall by 3/4 inches strong.

The saw is a great addition to the toy workbench from my prior Instructable.

Supplies

1/8” and/or 1/4” birch plywood

1/2” dowel rod

Wood glue

Laser cutter or scroll saw

Step 1: Cut the Parts

The toy saw is laminated from three layers, each of which you cut on a laser or scroll saw. The required pdf files are attached as layer1, layer2, layer 3, washer, and finally blade.

I used 1/8” plywood and doubled up layers 1 and 2 as well as the blade.

I also engraved some text and markings on the saw body and blade; it is your choice if you want to customize your own build!

Step 2: Assemble by Gluing the Layers

After cutting the parts assemble them with wood glue and clamps in the order shown in the rendered images above. The sequence is layer 1, layer 2, blade, layer 3, crank, axle, and washers. Make sure to insert the blade before gluing on final layer 3, as the blade won’t fit through the ‘blade guard'. When gluing the parts try to align them as well as possible. It will save some sanding later on and look better.

Glue in the dowels for the blade shaft (about 1 inch long) and crank handle (about 1.5 inches long) and use the plywood washers to strengthen those joints. The crank handle dowel needs to be flush on the backside of the blade, no washer there.

Step 3: Finish

After the glue dries sand the edges to remove the laser burn and make the toy smooth to the touch. Round the edges with sandpaper to prevent splinters from hurting your little one. If there are voids in the plywood edges fill them with sawdust/wood glue paste or with thick CA glue.

I left the plywood natural (unfinished) but you may stain or varnish it.

Have fun!