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Glass Saw: Rigid Diamond Wire Ring Driven by Its Rim
Martin

Created by

Martin

23. October 2026NO
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Glass Saw: Rigid Diamond Wire Ring Driven by Its Rim

Jesse Cogswell's ring saw (US 4,576,139, 1986) for glass, ceramics and stone. The blade is a rigid circle of wire coated with bonded diamond, standing upright through a cutting table. A rubber-tyred wheel on the motor drives it by friction round its own rim at 3000 ft/min or more, and twelve guide wheels on slots round an aluminium back-plate hold it true. Because it cuts with any part of its rim, the work can be turned freely for curves and inside shapes; a sponge in a water tray wets the wire. The patent sizes the ring from the thickest work to be cut (8 in ring for 3/16 in); the notebook does the sums. The picture: the patent's Fig. 1.
Advanced
3 days

Instructions

1

Cut and brace the back-plate

Cut the back-plate (2A) from aluminium plate, its upper part curved as an arc to shield the saw, stiffened by an angle (2B) along the top and a flat splatter strip (2C) at the front. Bolt on two front struts (21, 21A) and two side struts (22) and bolt them to the base. Ours: drill press.

Materials for this step:

Aluminium PlateAluminium Plate1 piece
Aluminum AngleAluminum Angle1 piece
Hex Bolt - Grade 8.8Hex Bolt - Grade 8.81 piece

Tools needed:

Drill PressDrill Press
Adjustable WrenchAdjustable Wrench
2

Cut the wheel-slider apertures

Cut slots (32) through the back-plate's arc at 0, 30, 60, 90, 120, 210, 240, 270, 300 and 330° round the ring's centre: two slots at 90° and 210° for the guide pairs, one at each of the others. The slots let each guide wheel slide to the ring.

Tools needed:

Drill PressDrill Press
3

Assemble the guide wheels

For each of the twelve guide wheels, stretch two rubber O-rings (27) into the grooves of a bearing wheel (26) with sealed roller bearings, and mount it on a shoulder bolt (28) with a washer, lockwasher and nut.

Materials for this step:

Guide RollerGuide Roller12 pieces
O-RingO-Ring24 pieces
Shoulder BoltShoulder Bolt12 pieces
Flat WasherFlat Washer12 pieces
Spring WasherSpring Washer12 pieces
Hex NutHex Nut12 pieces

Tools needed:

Adjustable WrenchAdjustable Wrench
4

Turn the drive wheel

Turn an aluminium disk with a hub, a bored axle hole and a deep groove round its rim, and seat a large rubber O-ring (23) in the groove as its driving tyre. Ours: lathe.

Materials for this step:

Aluminium PlateAluminium Plate1 piece
O-RingO-Ring1 piece

Tools needed:

Metal LatheMetal Lathe
5

Mount the motor and drive axle

Strap the electric motor (51) onto its pillow block (50) with fastening bands (52) and bolt the block to the base. Fix the drive wheel on the motor's axle (24) and carry the axle's end in an axle pillow block (24A, 24B).

Materials for this step:

Electric MotorElectric Motor1 piece
Motor Mounting BandMotor Mounting Band2 pieces
Bearing BlockBearing Block2 pieces
Steel ShaftSteel Shaft1 piece
Hex Bolt - Grade 8.8Hex Bolt - Grade 8.81 piece

Tools needed:

Adjustable WrenchAdjustable Wrench
6

Fit the ring and its guides

Stand the ring saw on the drive wheel's tyre. Bolt the guide wheels through their slots: each pair with a tension spring between its two wheels, each single with a spring to the back-plate's lower rim, the one at 330° pressing the ring onto the drive wheel. Set them against the ring, then tighten the nuts. Fit two horizontal roller-guides (17) at 150°, sprung together, just before the cut.

Materials for this step:

Ring Saw BladeRing Saw Blade1 piece
Extension SpringExtension Spring11 pieces
Guide RollerGuide Roller2 pieces

Tools needed:

Adjustable WrenchAdjustable Wrench
7

Fit the table, tray and sponge

Bolt the water tray (46) on four bracket supports (19, 20) by its four studs; put a ring-shaped sponge (47) in it and the cutting table (44) over it, the ring passing through centre holes reached by slots offset half an inch from a radius. Set the table top below the ring's centre line by the thickest work you will cut. Add water to the tray.

Materials for this step:

TrayTray1 piece
SpongeSponge1 piece
Aluminium PlateAluminium Plate1 piece
WaterWater1 batch

Tools needed:

Adjustable WrenchAdjustable Wrench
8

Fit the face shield and drip pan

Bolt the shield arm (41) to the back-plate and pivot a clear acrylic face shield (43) in its holder (42) on a locking screw. The base is a catchment for the coolant with a drain hole in one corner.

Materials for this step:

Acrylic SheetAcrylic Sheet1 piece
Aluminium PlateAluminium Plate1 piece
Drip PanDrip Pan1 piece

Tools needed:

Adjustable WrenchAdjustable Wrench
9

Ring size and drive speed

Loading Jupyter Notebook...

Materials

20

Tools Required

3

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