Dremel Cutoff Saw

This is a Dremel / Rotary tool cutting mount for precision cuts of rods, screws, bolts, drill bits, tubes and more.

I wanted to do the Pin Mod on my Voron 2.4r2 and I didn't have an accurate method to cut the pins to size. I ordered the recommended 2 rods that are G6 5mm x 500mm and have remixed this design for the purpose of this mod. You'll see that I'm using the two rods in the first cut, I think the improvements will work universally for anyone wanting to cut rods or tubes accurately. With a 38mm disc the maximum cut length is roughly 60mm depending on the size of the rod (and whether you use the guide with a cutout). 

If you buy a 60mm disc you may be able to cut much longer using the original clamp as a base raiser. With clever rotation of a pipe you can cut something way bigger.

This can also be used with the Dremel Flex, but I don't have one to test (part provided).

It can be clamped or bolted to a board/bench.

Improvements: 

• Refinements for printing.
• 5mm holes for shaft (tight tolerance)
• Hex Head bolts for clamp. With the original clamp I have called it a base raiser because you can flip it and use it to raise the cutting base. This means you can sometimes get through things you otherwise wouldn't. I have then included another clamp piece for securing the material which has only one side so as not to restrict cutting depth (but can also be flipped depending on what you are securing). 
• Cutting Guide Line for easy measurement. This could be enhanced with a diy measuring tape sticker or a bought one

Printing: Printed using standard Voron settings in ABS (high temp material recommended). There are tight tolerances on the holes and so you might like to print the hole test which will give you an indication of whether your printer is up to the task (one hole is for the guides and one for the base). The fit will be tight and you may need a 5mm drill bit if your print isn't perfect. I have added supports as part of the design to the Dremel Flex and Clamp and oriented all parts for printing. If you don't like the built in supports which may need a knife to remove, you can do “split to parts” in your slicer and let it add the supports. 

BOM:
1x 5mm shaft (85mm for hinge). Suggest two from here.
4x M5x30-40 Hex Head bolts
1x M5x40+ SHCS bolt for depth stop
5x printed wing nut things 3 wing or 2 wing for clamp. Thumb screw for the depth setting.
5x M5 nuts
1x 3d printer bed spring (ender 3 style);
1x kapton or aluminium tape for under cutting action to deflect heat
1x rotary tool compatible with Dremel accessories (I have a ryobi with an end piece that screws off for attaching to this). Recommend 38mm cutting disc. 
1x Other bolts for securing, clamps for clamping to table…etc

WARNING: Cutting metal pieces with rotary discs is dangerous, the disc can break and some parts of the cut material can be launched at a very high speed. Keep your hands and face away while cutting and use proper protective equipment (safety glasses, gloves and thick clothing).

I don't have a Dremel Flex. If you have one, I would highly recommend using it with this device to reduce risk and improve control. If you are tempted to extend the mandrel or use a large cutoff disc - don't!