$10 DIY Dremel /RotaryTool

A Rotary Tool is perhaps the most used tool. It can Cut, Grind, Sand, Polish, Engrave with the Different types of bits.This small little DIY Dremel is easy to hold and cut metal, Acrylic, Drill PCB. Sand And Engrave too.
It is Easy to make and is very powerful.
It can work both with an adapter or with any battery Lipo, Lead Acid.
Mostly It will come really handy for future projects.

This project is made for the build a tool contest , so if you like it do vote for it

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Component

Drill Chuck ::http://amzn.to/2mWX5M4

Drill Chuck Alternate link : https://goo.gl/8Z9dua

DC Motor: :http://amzn.to/2mWZQND

Momentary Switch : http://amzn.to/2mfMrLT

18 AWG wire :https://goo.gl/L3eD05

Epoxy glue :http://amzn.to/2niP3KC

M3 bolts https://goo.gl/008pi0

Attachment

Wood Cutting disk : https://goo.gl/m1X40Q

Abrasive Cutting disk :https://goo.gl/0Avubi

Drill bit : https://goo.gl/008pi0

Sanding Bit https://goo.gl/eRpX8c

Tool

3D Printer Used https://goo.gl/Xpp422

DIY Soldering Helping Hand https://www.instructables.com/id/DIY-Flexible-Sold...

DIY Fume Extractor https://www.instructables.com/id/DIY-Fume-Extracto...

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So Basically I started by designing the motor enclosure, I took a measurement of the motor diameter, the motor height, and motor shaft diameter.Then Using Fusion 360, I Started making a basic Sketch.
I then added the switch mount hole and air flow holes.
Now if you are new to 3D designing Instructables give you a good start with their instructable classes.
Jonathan Odom made a really good tutorial in it.

STL Files http://www.thingiverse.com/thing:2168240
I First sliced the STL using Cura with the following Setting

Temperature 195 C

Speed 85 mm/s

Raft & Support Disabled

Layer height 0.2

Infill 20%

The Print time took around 2 Hour 30 mins

I Used 18 AWG for the project as it will handle more current.Now before starting to solder it, we need to tin the wires.

To tin a wire, apply the tip of your iron to the wire for a second or two, then apply the solder to the wire. The solder should flow freely onto the wire and coat it (if it's stranded wire the solder should flow into it, and fill the wire). You may need to snip the end off afterward, particularly if you have put a little too much solder on and it has formed a little ball at the end of the wire.

The Motor I am using can handle voltages up to 24 V. This motor is a 550 motor but I have salvaged it from an old printer long ago.The only difference is has a brass gear on the shaft. Anyways I tinned the motor terminal first with a little solder, And then soldered the tinned wire, from the last step. Btw the whole motor easy holds by the helping hand.

The Next step is to solder the switch. Now the Switch is used, turn on and latched to the on state until it is pressed again .You can also use a momentary switch.
Taking the wires out from the hole I started to solder the wired to the Switch.
I used some heat shrinks to prevent shorts.
Then I fixed the switch in position .

I used A bit of epoxy glue to fix the motor in the place. To apply the glue we need to prepare it at first by mixing equal amounts of resin and hardener. The bond is really tough but it takes the time to cure, hours .apphours.
Once the glue had cured it is a hard bond.Alternately you can use some m3 bolts to fix the motor

I then put the motor in the enclosure, enclosure took the wire out of end part and then closen closure with the end cap. I Also Drilled and added the nuts later just be on the safe side befoe the glue dries. Then I fixed the chuck.I took some care to make sure the chuck fits perfectly aligned .After the glue cured it was time to test the Tool

Can it Drill?

Yes, it can drill.Tested on plastic wood and PCB

Can it Cut?

Yes, it can Cut Metal bolts, Nails, and Screw.
It can also cut Plastic and Acrylic.

It can also cut wood, but I have to test it with a new Saw blade.

Can it engrave?
yes, it can engrave easily.
Tested on Plastic.

It can also be used to sand, buff and polish .you will be seeing it more in future projects.
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