How to Build a Hot Saw

Are you interested in creating things out of wood? Have you ever heard of a Hot Saw but have no idea how it works or how to build a hot saw?

If so, we’ve got some great tips here for making your own hot saw and bringing new possibilities with woodworking into your life. 

How to Build a Hot Saw

With the right parts, knowledge, and time, building a hot saw can be an exciting adventure into the world of crafting with wood. This project is inexpensive to complete and very rewarding -you’ll gain satisfaction from building something useful by yourself! Let’s delve deeper into everything you need to know about building a Hot Saw today.

Tools and Materials You Will Need to Build a Hot Saw

  1. A chainsaw
  2. An angle grinder and an assortment of abrasive discs
  3. High temperature-resistant gloves, safety glasses, and a face mask
  4. Welding rod
  5. Heavy-duty drill bit
  6. Hammer and chisel
  7. Power drill
  8. Pipe wrench
  9. Drill press
  10. Metal file
  11. Bench vice
  12. Pipe cutter
  13. Tin snips
  14. A miter saw or table saw
  15. High-temperature-resistant paint or coating suitable for the type of metal used.
 Disassembling the Chainsaw

Step-by-Step Guidelines on How to Build a Hot Saw

Step 1: Begin by Disassembling the Chainsaw:

Before you can begin building your hot saw, you need to start by disassembling the chainsaw. First, unplug it from any power sources and put on the appropriate safety gear. Remove the chain from the bar and sprocket of the saw. Unscrew all screws necessary to remove the cover plate, air filter, recoil starter, and spark plug. Now you are ready to move on to the next step of the hot saw building!

Step 2: Prepare the Chainbar for Modification:

Using your angle grinder, begin to grind down any protrusions on the chain bar. Hold the chain bar in a bench vice while you work to ensure it is stable and secure. This step is essential to ensure that the chain bar can be mounted properly on the frame of your hot saw. Continue until all protrusions are removed, and then use a metal file to make sure everything is even and smooth.

Step 3: Cut and Weld the Frame:

Now you are ready to start building your hot saw’s frame. First, measure and cut your steel tubing with the pipe cutter. Once you have all of the necessary pieces, use a welding rod to join them together securely. Make sure that all weld points are even and strong! When cutting, make sure to wear safety glasses and a face mask at all times.

Step 4: Create the Mount for Your Chain Bar:

Next, use your drill press to create the mount for your chain bar. Drill holes in the steel frame of your hot saw where you will attach the chain bar with screws or bolts. Make sure that these holes are aligned properly and securely. If the holes are not drilled correctly, the chain bar could become loose and cause injury.

Step 5: Connect the Chain Bar to the Frame:

Once your drill holes are complete, use a pipe wrench to connect the chain bar to the frame of your hot saw. Make sure that it is securely fastened and in place before continuing on.  While connecting the chain bar, wear high temperature-resistant gloves.

Step 6: Attach the Handle and Test Your Hot Saw:

Before finishing up, attach the handle of your hot saw. This is essential for controlling the direction in which the saw moves. To finish, apply a high-temperature paint or coating to all metal surfaces to protect them from rust or corrosion. Once you are finished, test out your new hot saw and start building with wood!

Attach the Handle of Your Hot Saw

Congratulations – your hot saw is now ready for use! With the right tools, knowledge, and time, you can easily build a hot saw to get started on some exciting woodworking projects. Be sure to follow all safety guidelines and wear the necessary protective gear when working with any kind of power tool. Have fun crafting and enjoy the satisfaction of building something by yourself.  Good luck!

Precautions Need to Follow for Building a Hot Saw

1. Wear appropriate safety gear while building a hot saw. This includes heavy-duty gloves, goggles or a face shield, and protective clothing that covers your arms and legs. It is also important to wear hearing protection for the loud noises generated by the saw.

2. Make sure any combustible materials, such as fuel tanks and wood, are kept away from the saw when it is being used.

3. Securely mount the saw to a surface that the heat of the blade or exhaust will not damage. Make sure this surface is level and stable so that there is no risk of tipping or wobbling during use.

4. Use an appropriate fuel tank for the saw. If a gasoline-powered saw is being used, use an approved gas can that is free of leaks. Use a proper storage container for a diesel-powered saw with no signs of rust or damage.

5. Set up adequate ventilation in the area where the hot saw will be used to disperse fumes and exhaust.

6. Check that all components of the saw are properly attached and working correctly before use. Ensure the blade, throttle cable, oil tank cap, and fuel line connections are securely attached.

7. Always keep your hands away from the hot saw blade while operating it to prevent serious injury.

8. Make sure to read and follow the manufacturer’s instructions for safe operation.

9. Periodically check the saw blade’s condition to ensure it is not overly worn or damaged before use. Replace any parts that are worn out or no longer functioning properly.

10. When storing the hot saw, ensure it is stored away from flammable materials to prevent fires.

Use an Appropriate Fuel Tank for the Saw

These are some general precautions to follow when building and using a hot saw. Following these guidelines can help you build and use your saw safely and protect yourself and others around you from harm.

Additional Tips to Build a Hot Saw

1. Purchase a high-quality spark plug for your hot saw. A spark plug with a good electrode gap will ensure that the ignition system functions properly and is able to provide the proper amount of spark needed for your saw to run smoothly.

2. Make sure you use the correct oil for your hot saw. Different types of chainsaws require different types of oil. Make sure to use the type of oil recommended in your owner’s manual.

3. Keep the air filter clean. The air filter should be checked regularly for any dirt or debris that might have gotten stuck in it, as this can affect the performance of your saw. If necessary, replace your air filter with a new one.

4. Make sure your hot saw has the proper mix of fuel and oil in it. This will ensure that your saw is running at its optimal performance level and that you get the most out of it for each use.

5. Sharpen the chain regularly to keep it in top condition and ensure its performance. Dull chains will cause the saw to be less powerful and efficient in cutting.

6. If you are going to use your saw on a regular basis, make sure to check it thoroughly before each use. This includes checking the spark plug, oil levels, filters, chain tension, and other components of the saw for any signs of wear or damage.

7. Regularly lubricate the bar, chain, and sprocket to ensure they all move freely and efficiently. This will keep your saw running smoothly and help prevent damage over time.

8. Always use proper safety equipment when using a hot saw, including goggles, gloves, and other protective clothing. Make sure to read the safety manual before using your saw.

Use Proper Safety Equipment When Using a Hot Saw

By following these tips, you can ensure your hot saw runs smoothly and efficiently for every use. With regular maintenance, your hot saw will last for many years and provide reliable performance with each use.

What Are the Benefits of Having a Hot Saw?

Having a hot saw can be incredibly beneficial when it comes to cutting through tough materials. Hot saws can apply extreme heat and pressure while cutting, making them ideal for difficult jobs. With a hot saw, users can easily cut through hardwoods, steel, aluminum, copper, and more with very little effort. The main benefit of having a hot saw is that it can save time and effort when completing cutting tasks.


Building a hot saw can be a labor of love, and if you have patience and follow the instructions carefully, you will have clear knowledge about how to build a hot saw with basic tools. 

Once constructed, you can begin cutting your favorite materials and practice proper safety precautions. Although it may take some time to become comfortable with its operation, the benefits of having an at-home saw become apparent quickly when you can succeed in each project.

A hot saw is an excellent DIY investment that could not only make woodworking easier but also help hone your skills as a hobbyist or professional alike. Whether operating one of these specialized tools is something new or has been done many times over, the enjoyment of getting it right is something all woodworkers can share in.

Photo of author

Enrique Howard

Hi, I am Enrique. I started my professional life as a handyman and did a lot of external and internal repair of home and office with a little bit of electric and plumbing support. I have extensive experience in tools testing such as drilling, turning, milling, and non-conventional machining like EDM. So let me help you on your journey towards becoming an enlightened DIYer with amazing tools that you can use on your project.

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