How to Make a Rotary Tool Guard out of Plastic

How to Make a Rotary Tool Guard out of Plastic

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One of the biggest risks associated with using rotary tools comes from pieces breaking off while cutting and impacting the face and eyes.  This is why it’s so important to wear protective eyewear, as pieces are bound to fly off almost every time the tool is used.  A guard over the top side of the cutting blade provides a significant layer of protection against flying debris.  Some models have them pre-installed whereas you can easily find accessories to snap on yourself.  However, they can be expensive. 

You can make your own guards for next to nothing with little more than an empty plastic soda or water bottle by following the steps below.  It will be rudimentary, but it may also be just what you need to get the job done as safely as possible.

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Getting Started

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The first step is to determine the size of the guard you want to make, and mark off this spot along the top portion of the bottle.  Next, cut around the bottle until the top detaches, and trim it off as necessary.  The next step is to remove the screw/bolt and cover that holds accessories on to the rotary tool.  Once the bare rod is exposed, the next thing to do is trace an outline of its shape and diameter onto the outside of the bottle cap.  Ideally, you want to be able to slide the cap over the rod of the tool and have it rest against the back wall.  However, it’s important that the cap is anchored to the portion of the rod or tool that does not move, otherwise the guard will spin along with the attachment. 

Once you’ve traced the outline on the cap, cut it out with a razor blade or box cutter and test its fit against the tool.  Make adjustments or improvise as necessary in order to create a stable and sturdy anchor that won’t be prone to falling or becoming dislodged as you use the tool.

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Customizing the Guard

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The next step is to customize the top piece of the bottle according to your specific needs.  It is generally easier to attach the bottle to the cap once it’s anchored to the tool before making modifications.  However, you can trace the outline of the section that you want to remove from the bottle and cut it on your table or in a clamp if you prefer. 

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In any case, you can make the guard as wide or as narrow as needed.  You can simply cut out a notch that will expose the head, or you can create a more professional-looking guard that tapers along the back and center where it anchors to the tool.  Just make sure that you allow enough room for the cutter to work on the job that you are trying to perform.  It’s also important that the segment of the guard is long enough to provide ample protection on top as well. 

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You can use scissors, a razor or a combination of both to make the cuts as rough or as precise as you like.  Smooth over the edges when you’re finished, attach the guard, and secure the cutting head in place.  Test the tool by pointing it away from you just in case the guard gets caught up in the spinner and pieces accidentally break off.  Make adjustments as necessary, and you should be good to go. 

Try this out for yourself, and consider making a few different guards to use with different cutting heads.  This simple modification can save you time, money and help to reduce injuries while working with rotary tools, and it’s a good one to always keep in the back of your mind.   

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