How to make a carrying case for circular saw blades

Written by josh baum
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Some circular saw blades are sold with durable plastic or vinyl protective cases, but many are sold with no protective gear at all. Leaving your saw blades unprotected in storage can be detrimental to the integrity of your blades; all it takes is a few nicks and a little dulling to render a once-perfect blade useless. But with the method described below, you can make a cheap, low-tech carrying and storage case for blades of all sizes. It's just as effective as the heavy-duty models sold in stores, but you'll save big by making your own.

Skill level:
Moderate

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Things you need

  • Electric circular saw
  • Ruler or measuring tape
  • Pencil
  • Plywood
  • Power drill
  • 3/8" drill bit
  • 3/8" bolt, washer and wing nut combo
  • Cardboard
  • Utility knife
  • Nail

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Instructions

  1. 1

    Find or buy a spare piece of plywood; any thickness or size will do, and scrap pieces will work just fine. Measure and mark a section about 12 inches square, using a ruler or tape measure and a pencil.

  2. 2

    Use your electric circular saw to cut out the square of plywood. Then, on any side of the square, cut a carrying handle into the wood. The handle should be a rectangular hole that is at least 6 inches wide and 2 inches tall, although you can easily "eyeball" this cut without measuring. Cut the rectangle about 1 inch from the edge of any side of the square, and do your best to centre it in the middle of the side.

  3. 3

    Lay a piece of cardboard over the wooden square and slide it down so that it doesn't cover the carrying handle. Use a utility knife to cut the cardboard to the same size as the square, excluding the top few inches where the handle has been cut.

  4. 4

    Repeat Step 3 if necessary by cutting additional pieces of cardboard. You will need one piece of cardboard for every saw blade you wish to store.

  5. 5

    Affix a 3/8-inch drill bit onto your electric drill and bore a hole through the centre of the square of wood. Again, this is a fairly crude project, so there's no need to measure and find the dead centre.

  6. 6

    Stack the pieces of cardboard evenly and set the square of wood on top. Push a sharp nail through the hole in the wood so that it pierces all of the layers of cardboard underneath, then extract the nail and set the cardboard aside.

  7. 7

    Remove the washer and wing nut from your bolt and slide the bolt through the hole. Then slide your largest circular saw blade over the bolt, and slide a piece of cardboard on after it. If you have additional saw blades, put them onto the bolt the same way and alternate layers of saw blades and cardboard. Your last layer should be a piece of cardboard to protect the outermost blade.

  8. 8

    Place the washer over the bolt, followed by the wing nut. Tighten the wing nut all the way down. You can now carry your blades around by the carrying handle, and you can easily store this compact system anywhere in your shed, garage or workshop.

Tips and warnings

  • Use extreme caution when using any sharp power tools such as electric circular saws and power drills. Follow all of the manufacturer's safety guidelines.

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