What do you do with the old junk you have lying around? You can make a beautiful table lamp with an old circular saw, just using a little creativity.
I bought a classic circular saw from Black and Decker years ago thinking it would be a useful addition to my shop, but once I received it I realized that it had a spindle that didn't fit modern saw blades and the motor was quite weak.
A lamp! My grandfather was always building lamps from unique items.
I have a set he made from old brass oilers and another made from the steam whistle from his old sawmill.
The following are step-by-step instructions on how to turn this old junk into a cool looking lamp.
Steps to make a table lamp with an old circular saw
#1: Put the pieces together



Many of the parts can be found used at your local junk store or removed from old lamps.
Saws can be found on eBay, at goodwill stores, or at many antique stores.
The full list of components I used is below.
- A vintage saw, preferably all aluminum construction.
- Also 1 Lamp Holder
- 1 Lampshade
- One cord (I used a 3-wire industrial style plug to preserve the saw look instead of a typical 2-wire lamp cord)
- Lamp stem. I used PIST08 from Grand Brass, they have a variety of finishes and lengths available, be sure to use the long thread so you have enough thread to screw to the saw.
- 3 Grand Brass NU234 Stem Nuts
- 1 saw blade. I used a scrap. Some saws may have the blade in them.
- Polishing for metal
- 1 Base board
- 4 #8 3/4″ pan head screws to secure the saw to the base
- Wood finish of your choice
Step 2: Gather the tools

This project can be done with fairly basic tools. If you have the luxury or a pipe cutter or bender, they are good to speed up a couple steps but not necessary. The tools I used are.
- 1/8″ pilot bits for flat head screws, 3/16″ for drilling mounting holes in the base and 7/16″ for the lamp stem.
- Grinding machine with cutting wheel and grinding wheel.
- Circular saw
- Drill
- Wire cutter
- Screwdrivers
- Adjustable wrench
- Multimeter
#3: Disassemble and remove the switch and the old cable





- The first step of this project was to remove the old wire and switch or any other parts that may interfere with the assembly of the lamp stem and the new wire routing. If your saw's cord is in good condition, you may be able to reuse it for your lamp; However, in most cases, with a saw this age, the cable will have cracks and cuts and will need to be replaced.
- Removing the old cable will involve some level of disassembly of the saw; In this case, the handle was a two-piece design and I was able to remove the 4 screws shown to access the cable and switch.
- Use a set of side cutters to cut the wires leading to the motor and remove the wire and switch.
- I wanted to retain the switch trigger for visual effects, so I used a saw to cut the trigger off the switch body. A dremel or grinder with a cutting wheel would also work to cut the trigger.
- Once the trigger has been separated from the switch, it can be remounted to the saw.
#4: Lamp Stem Assembly




- I decided I wanted to mount the lamp stem outside of the handle, this allowed me to place the lamp near the center of the saw and route the lamp cord the same way as the original saw cord.
- Depending on your saw model, you may choose to mount the shank in a different location.
- Determine location to mount the stem.
- Drive the mounting hole with a 7/16″ drill bit.
- I recommend drilling a 1/8″ pilot hole first and then enlarging to 7/16″, press the bit lightly so the bit doesn't grab and break the aluminum.
- Bend the stem as necessary so the lamp is level.
- A pipe bender is ideal; However, if one is not available, you can hold a vise and slide a larger piece of tubing over the stem to bend it, being careful not to bend the stem when bending with this method.
- I squeezed the stem 3 times at different points and made 3 small curves for a smooth sweep.
- Once the shank has been bent to the necessary angle, mount it to the saw.
- Thread one nut onto the shank about 3/8″ so there is enough thread protruding from the saw and install a second nut to secure the shank to the saw.
- Tighten the nuts with a suitable wrench.
#5: Wiring the lamp







- The cable I used was taken from an old stereo amplifier and the colors differ from a typical cable which would have a white neutral and a black hot wire.
- Remove the outer insulation of the cable.
- You will need to remove enough insulation from the wire to feed the neutral and hot wire to the lamp stem.
- Measure the length of the lamp stem and add approximately 2 inches to that of the lamp fixture wiring.
- I have found that the best way to cut the insulation is to bend the wire into a loop and lightly cut the outside edge of the loop.
- Once the insulation has been cut, pull the outer insulation of the wires.
- Insert the wires through the stem of the lamp and pass the wires through the saw and out of the saw.
- I used the original strain relief and wire clamp to hold the cables.
- Hold the ends of the cables and connect the ground.
- Strip about 1/4 inch from the end of the wires to attach it to the lamp base.
- I also attached the floor to the original floor location.
- While most lamps do not have a ground connection, it does add a level of safety, and since I used the 3-wire cord to preserve the look of the saw, I was able to ground the lamp.
- Remove the base of the lamp fixture, in most cases this will just clip on, but some fixtures may use screws.
- Pass the wires through the base of the fixture and screw the base onto the stem. I used a nut to jam the base so it wouldn't rotate.
- The socket will normally slide off the outer tube allowing access to the terminals.
- You will notice that one terminal is lighter in color than the other, indicating that it is the neutral terminal and should be connected to the white wire in a typical cable.
- I added pictures showing another outlet and a cable with black and white wires.
Note:
- Test the wiring.
- If the lamp is not connected correctly, it will continue to work; However, the neutral wire will be switched in place of the hot wire, leaving the outside of the socket energized at all times, which is dangerous.
- I made a quickCheck continuity with a multimeter to ensure it was connected correctly.
- See attached photo for more instructions on this test.
#6: Modifying the Sheet




- I wanted to have a blade on my saw and make it look like I'm cutting a piece of wood to do this.
- I wanted the blade to sit in a notch in the wood base, but I didn't want the notch to cut all the way through. my board.
- I cut the bottom of the blade where it meets the notch.
- In the pictures, I'm using a plasma cutter to do this, but if you don't have a plasma cutter, a cutting wheel on an angle grinder will work.
- Install the blade on the saw and place the base of the saw on your board, determine how deep you want the blade to sit in the base and mark the blade with a pen or sharpener.
- Place the line to cut the blade and cut with an angle grinder.
- Use the angle grinder to clean the cut if cutting with a plasma.
- Use an angle grinder to round off the sharp edge of the teeth that will be exposed so little fingers don't get cut while admiring your lamp.
#7: Prepare the base and assemble the saw







- The base can be any board of your choice. Three-dimensional yellow pine lumber from your local hardware store would also work and you can finish it with stain or clear coat to your liking.
- Reinstall the modified blade into the saw and place the base of the saw on the board with the blade hanging over the edge and use a pencil to mark the depth.
- Put the work circular saw on the board in the same way and set the depth slightly below your mark.
- Determine where you want to place the saw lamp on the board and place a mark or measure the distance from the edge.
- Place a mark on the front of the blade indicating where the notch should stop.
- Use a straight edge to trace the line to be cut.
- Cut the notch using your good circular saw.
- Remove the mark you used to set the depth and the mark you placed indicating where the notch should stop.
- I left the rest of the line I marked on top so the saw looks like it is cutting the board.
- Find 3-4 suitable locations on the base of the saw and mark and drill the holes to attach the saw to the base.
- Place the saw blade in the notch and place the saw where it will rest on the base and drill the pilot holes with a 1/8″ bit. Drill pilot holes to a depth of 3/4″-1″.
- Before you assemble the saw, do any cleaning or polishing you want to do, this is one for a quick polish and then polish it with a rag.
- Mount the saw to the base with the flat head screws.
#8: Enjoy!!



Finally add the shade and a cool looking bulb to your lamp and you are ready to enjoy.
Without a doubt this table lamp with an old circular saw is an interesting DIY job that you can do.
The finished product will be something fresh that you can enjoy for years and possibly hand out to children like my grandfather did with the greaser and steam whistle lamps he made.
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