DIY band saw drawings and assembly

Types of band saws

Before assembling a band saw, it is worth examining their types. Experts distinguish between these types of similar devices:

1. toothless band saws: they have great productivity and are able to process metal products. Their peculiarity is that they have small teeth. The product is cut due to high heat and friction;
2. serrated band saws: for processing plastic products and wood. The main feature of cutting blades in such devices is considered to be their closure;
3. electrospark band saws: used mainly in large factories that handle huge amounts of wood.

Preparing to assemble the sawmill

Of course, in our time, you can purchase both ready-made materials and an industrial factory band sawmill. But this is often associated with high financial costs. It is more profitable and practical to assemble a band saw according to ready-made drawings with your own hands. This is especially true if you have a private house or garage. In this case, the sawmill is justified in a domestic environment.

To assemble your own sawmill, you need to have drawings, a cutting blade, some details and study a little theory. The diagram should reflect the dimensions and materials used.

Tool size selection

The length and width of the saw depend on the corresponding machine parameters. For clarification, you need to use the recommendations and instructions for the machine, as well as do-it-yourself band saw drawings for wood.

General recommendations when choosing the best option:

1. For longitudinal cutting, wide band saws are used, since they have the most even cutting.
2. Thin workpieces require thin saws. The thicker the saw and the thinner the part, the more likely it is to damage the workpiece.
3. When cutting fillets or shaped cuts, the width of the blade must be less than the radius of the fillet. The width of modern saws ranges from 14 to 88 mm. Usually 35-40 mm is enough for most jobs.

Tooth set value

Tooth pitch is the distance between the sharp edges of the saw. For the correct and effective use of the tool, you need to adhere to the general rules:

• When cutting thin materials, a saw with coarse teeth is required. In this case, the pitch of the teeth must be uniform.
• If the cutting surface is long, a constant, frequent step should be suitable for cutting.
• For cutting natural or synthetic webs, we need blades with variable teeth. Such a saw, when working with a soft structure, will not clog and the working speed will increase.

The quality of the cut depends on the setting of the teeth. The better the wiring, the lower the vibration level and the longer the saw itself will last:

• A wavy profile is suitable for working with thin materials or small workpieces.
• The standard profile is used for contour cutting or processing of volumetric parts. This profile has an alternating arrangement of cutters in different directions of the blade, with one segment located in the center.
• The teeth, located in pairs on both sides, form a variable profile. It is characterized by reduced stress on the cutting edge. The unit itself is more expensive, but more durable.

Before purchasing a specific saw, you need to find out if there is a possibility of re-sharpening and how many cycles the material of the blade can withstand.

In accordance with the material, there is the following classification of canvases:

1. Bimetallic. For working with stainless steel or strong alloys.The tape has increased strength.
2. Diamond. This is the processing of stone material, various minerals. Diamond, quartz, marble.
3. Carbide. Cutting difficult-to-machine alloys.
4. Tool steel band. An excellent choice when cutting simple materials. This type of canvases is most often used in small workshops or at home.

Sawing machine operating tips

In order to assemble even the simplest band unit for a mini sawmill, for example, such as described in the article, you will have to pay a certain amount of money for a variety of parts. Even if you have an electric motor on your farm with suitable parameters from old equipment, you still need to buy steel profiles, lumber, pulleys, belts and blades, and this will also cost a lot. But if you follow all the rules of operation, then you can very quickly recoup all costs, as well as earn a certain amount of capital.

Checking the tension of the cutting blade with a tensometer

Here's what the experts recommend:

First of all, you should correctly tighten the saw band - this depends on its thickness and width, as well as on the grade of steel. But in order to make the tension most optimal, you need to use a special device called a "tensometer" (see photo above). Most likely, you will not have it, but the device can be borrowed or rented in order to conduct at least one-time testing, and then it will be possible to do it "by eye".
Do not rely on the fact that the blade can cut continuously, for example, from morning to lunch or even until evening - this is not the case. It is best to stop the machine after two to three hours of operation, and then, after removing the saw, hang it in a free state (without tension) for 10-12 hours. This suggests that it doesn't hurt to have multiple canvases, especially if you have a lot of work to do.
If you work with dry blanks, then this does not imply any problems, but when sawing (dissolving) fresh wood, resins are released that clog the teeth, the tape quickly overheats and may even burst. To somehow mitigate such a negative factor, they use an impromptu lubricant: at positive temperatures, this is ordinary water with a detergent, and in frost, diesel fuel with oil.
At the end of the work, it is imperative to loosen the blade tension to protect against the effects of thermal deformation.

Steel expands when heated, therefore, when it cools (read narrowing), imprints will remain at the points of contact with the pulleys, which will significantly reduce the wear resistance of the saw.
Observe the sharpening standards, that is, the teeth must always be sharp and have the same set.
Keep in mind that any sawing machine is potentially hazardous to health, as careless movement or loss of alertness during fatigue can lead to serious injury and there are many examples of this. Therefore, it will be much safer if all moving parts (pulleys, blade) are covered with a protective cover.
The location of the machine is of great importance for safety.

Nothing should interfere with working with long workpieces, as this can lead to a breakage of the cutting band and even serious injury.
After injury, the phrase “I didn't notice” is often the result of a lack of lighting in the workplace. Sometimes the machines are installed on the street under a canopy without the proper power of lighting devices (they cost one light bulb for 60-80 W), therefore, in this case, you can work only during daylight hours. But it is best to install some kind of reflector, directing it to the desktop (if there is a possibility of adjustment, then this is even better).
Take care of the grounding of the electric motor and connect it through an RCD (residual current device) or at least through a differential circuit breaker - this can protect against injury.The fact is that with an electric shock, a person loses control over the body and the likelihood of limbs falling into the zone of action of the saw band increases.
The site for the workplace must be dry and hard (concrete screed, asphalt), and if the unit is on the street, then this site should be raised at least 3 cm above the ground level so that it is not flooded by streams during heavy rain;
Place a dielectric rubber mat under your feet when working.

Homemade band saw - the craftsman explains the machine

Operating tips

1. Tighten the saw blade correctly. Exceeding the allowable force will reduce the tool life. For control, you can use special devices. The saw should not be in operation for more than two hours, after which it must be dismantled and suspended for a day to relieve residual stresses.
2. Be sure to use a band lubricant. In warm weather, you can use water with the addition of detergents such as "Gala", "Fairy", etc., and in winter - a mixture of kerosene or diesel fuel with engine oil in a 5: 1 ratio or chain saw chain lubricant.

3. Be sure to release the saw tension after finishing work. This will prevent fatigue from forming on its surface and will extend its service life.

4. Use only properly sharpened and set tools. In the absence of experience in this area, you can use the services of specialized offices. As a rule, their representatives serve more than one sawmill in your area.
5. Do not work with freshly cut wood. Let it dry for at least one month. In addition, clean the logs of dirt and sand before work, and even better remove the bark.

Band sawmill at home

Wood is the most popular material in construction, which was used by our ancestors. And, it should be noted that it still remains in demand. There are many people who want to build houses from wood rather than concrete.

Even a layman understands that the construction of such facilities takes a lot of time and is quite costly. It was in order to achieve savings on these operations that woodworking machines were invented.

Although companies today offer different types of sawmills, each of them is designed to solve one problem - processing logging. But each does it in its own way.

If you have a band sawmill at your disposal, which you can make with your own hands, then you can not only engage in wood processing for personal purposes, but also derive additional income from this.

You can negotiate with interested parties on the production of the required volume of products and easily cope with this task. You will be able to fulfill any order, regardless of whether it will be a gazebo or a bathhouse. All you need to do for this is to take the workpiece and process it, after which you can use it for its intended purpose.

What can be made on a band sawmill

This question is asked by many masters who have heard well about the popularity of band sawmills. Once again, we recall that today such devices are presented in large numbers, but it is no coincidence that the band sawmill is the most popular.

The current situation can be explained by the fact that this equipment has many advantages that are relevant for the masters. First of all, a sawmill of this design can process workpieces from any species of wood, including deciduous and highly resinous ones.

Another feature of the band sawmill is that it can produce a fairly wide range of products:

1. Edged and not edged boards.
2. Bars.
3. Veneer.
4. Lafet, etc.

If you wish, you can create blanks for their subsequent use in the manufacture of furniture, glued beams, boards and other products.Having a band sawmill in your workshop will greatly simplify the process of woodworking.

A design of this type is appreciated by many, including the fact that it allows you to minimize the loss of logs to sawdust. Therefore, if you can make a band sawmill with your own hands, observing all the rules, then you can be sure that after processing the blanks, unpleasant waves or bristles will not appear on them.

DIY band sawmill: drawings and design

Do not rush and immediately move on to the practical part of making a band sawmill with your own hands. First, you need to study the design and draw up a simple drawing. This must also be done if you want to make a disk or tire sawmill.

The constructional diagram of this equipment is quite clear and simple. Therefore, you can easily add the components you need to it to perform additional operations that you will have in the course of work.

In other words, you have the opportunity to make the simplest version of the sawmill, which provides for the possibility of manual feeding of the workpiece. Alternatively, you can opt for a more complex version, creating a high-performance device according to an individual drawing, equipped with automation and special sensors that simplify the work of processing workpieces.

The main element of the sawmill, both disk and tire, is a frame with guides. For its manufacture, welded soles are used, in which movable rollers are placed. With any version of the band sawmill, the bed is always U-shaped, and it is made by welding two channels together.

In this case, the drive pulley is welded on one side of the frame in a stationary state, and the second is attached to the other end in a movable position. The installation of the guides is carried out strictly in the center and they themselves are collapsible.

This must be considered if you intend to transport equipment in the future. In general, making this tape structure with your own hands is a rather lengthy process. However, if you manage to do everything right, then you will get a very useful assistant in your workshop.

What materials are needed for manufacturing?

It should be noted that not the entire structure can be built from improvised means. Therefore, before making a band saw, you should assemble the necessary parts:

1. Wooden boards, chipboard, MDF or plywood. These materials are used to make the frame and the saw stand, as well as the pulleys.

2. Sheet steel for the production of cutting blades or a ready-made part that can be purchased at the store.

3. Channel and steel bar. These parts are used to manufacture the support frame and the axle on which the pulleys will be mounted.

4. Sheet rubber. It is used to protect wood.

5. Strong belt that will ensure the rotation of the wheels on the machine.

6. Polyurethane adhesive for joining some parts.

7. Fasteners: self-tapping screws, brackets, bolts, washers and rubber gaskets.

8. Bushings.

9. Electric motor. You shouldn't buy a very expensive model. Just decide how much power the machine should have.

Thus, a band saw can be constructed with your own hands. Drawings of this structure should be done, calculating each step as accurately as possible. Naturally, you can find all the schemes ready-made.

How to make a saw?

If you need a saw, but the price announced by the seller "bites", then it's time to think about how to create a tool with your own hands.

A saw designed for metal cutting will require a more powerful electric motor, for example, as in the Makita models, which will also be useful if you are going to saw thick trees.

In the case where a more powerful tool is required, it is best to make a pendulum frame.Pendulum variations are not only more powerful but also very effective.

In order for the frame of the apparatus to be stable, steel corners must be used for its manufacture, not wooden corners.

The frame is the base on which all cutting and rotating mechanisms are installed, so make sure it is strong.

Before you start assembling the saw with your own hands, look at the diagrams with its device: you can focus, for example, on the Makita company, because it is a high-quality and functional device for metal processing.

Every homemade cut-off saw must be placed on a stable surface, usually a table.

It is necessary that it be correctly fixed, because if it staggers, then this can not only ruin your workpiece, but also be dangerous for the master.

The tool table should be special, and it is also better to do it yourself. For the bed, you can use an old table from the kitchen, or metal or wooden trestles.

The tabletop can be made from metal plates 4 mm wide. You will need two of them to work. Alternatively, you can use thick beams that need to be tied with a plywood jumper.

When joining materials, remember to leave a gap of at least 10 mm between the materials.

The most important thing when working is to keep the edges of the insert parallel to each other, otherwise the end saw will not function properly.

When attaching the tool to the tabletop, the saw should be in the center of the gap, and the sheets should be located on its two sides. In the table you need to make holes in which the saw will be fixed.

After installing it, you need to secure the motor for the miter saw to work. If you've made a small saw, the easiest way is to attach it to the motor shaft.

Video:

However, the tool is not suitable for cutting thick metal, therefore, if you understand that low power will not be enough for you in your work, then immediately make a more powerful tool.

You can use a bicycle spindle as a transmission mechanism for a homemade saw. It includes bearings and a shaft, which you will also need in your work.

You can use a hacksaw to cut the spindle off the bike. A sprocket must be installed on the bicycle shaft. The best part for this is a part belonging to the D6 or D8 motor.

The saw blade must be attached to the spindle, however, before doing this, you need to decide on the diameter of the device.

The diameter of the sleeve must also match the diameter of the other parts so that they all fit tightly together.

It is also necessary to install a plate on the spindle body, the thickness of which is at least 5 mm. The sprocket is attached to a shaft that has a homemade saw.

The sprocket should be 2.5 times the size of the spindle.

The saw chain is put on the body last, after all other parts have been correctly installed and secured.

The price of the parts that the cut-off saw requires will be much lower than the price of a finished saw, for example, from Makita.

From the tools you will need:

1. table;
2. several plates;
3. several bars and jumpers;
4. old bicycle spindle;
5. sleeve for transition;
6. star;
7. chain;
8. shaft.

Some of these tools are probably already in your garage, while others can be obtained very cheaply.

If you are not confident in your abilities, then it is better to purchase a ready-made tool.

Moreover, the price of some Makita models is quite acceptable, and at the same time they have wide functionality.

Before buying a saw for cutting metal, research the offers on the market and read about different models of tools.

It is better to choose an already proven device, for example, a Makita saw, which has long established itself on the market. The price of both circular and pendulum saws is quite affordable for a person with an average income.

Features of the saw application

Even after you can make the presented design, you should learn how to use it correctly. For example, try to follow all necessary safety rules. Please note that in some cases the blade can burst, so if you are not sure about the strength of its attachment, then do not get too close to the machine.

Observe the following rules for using the device:

- The larger the workpiece to be cut, the larger the saw teeth should be.

- It is better to use universal cutting belts. In this case, you do not have to change the canvas every time you need to process any other material.

- Before making the device, you must definitely choose the place where it will stand. This takes into account the size of the room, the presence of electrical wiring. Naturally, this place should be well ventilated.

- Try to tighten the cutting band as much as possible before work. Otherwise, the machine will not only fail to perform its functions, but also become hazardous to health.

- The unit must not run for more than two hours in a row. After that, the tape is removed and left alone for at least a day.

- After prolonged operation, the machine must be lubricated. Find the right substance for your car.

- The correct set of teeth is obligatory.

That's all the features of making and using a band saw. Please note that this device requires proper care. If you see that it is not working properly, then it is better to postpone the start of its operation. Be attentive and careful.

Stages of welding

Cutting

To begin with, the saw blade must be cut to the specified length. Different tools can be used for cutting. We recommend guillotine shears as they give the smoothest cut. The cut itself should be located at the top of the teeth. Do not forget to leave about 1-2 millimeters from the side of the cut for the draft.

To achieve an accurate cut, you can use the technique shown in the picture below. After cutting this way, the ends of the saw will be straight and fit perfectly. And this directly affects the quality of the weld.

Stripping

After cutting, the ends of the saw should be cleaned. This is the standard preparation of metal for welding. Clean metal from dirt and traces of corrosion. Then degrease with any solvent. For example, acetone. Then clean the edges with an abrasive material. We use sandpaper. Make sure there are no burrs on the edges. Ideally, they should be smooth and even.

Installing the saw into the clamps

Above, we could already familiarize ourselves with the components that make up a band saw welding machine. We said that there is a clamping mechanism. It is in it that you need to install the saw blade. The clamp has a movable and a fixed part. Set one end of the blade to the movable one, and the other end to the stationary one. There is free space between the clamps. You need to install the canvas so that its joints are exactly in the middle of this space. Naturally, the joint must be smooth and precise.

Selecting a welding mode

Next, you need to select the welding mode. If you have a simple welding machine, then all the parameters must be set manually. The welding mode is selected based on the size of the saw and its section. The larger the cross section, the higher the value of the welding current. These are general guidelines.

Usually, an instruction is attached to the welding machine, in which all welding modes are prescribed, depending on the size of the saw blade

Also pay attention to the setting of the current pulse rate. For budget models, it must be controlled manually, otherwise the metal will heat up too much

The recommended time for supplying current is 1-2 seconds. In more expensive devices, this parameter is adjusted automatically.

Welding

Welding for band saws starts with turning on the machine.The band saw welding machine is started depending on the model. It can be a separate button or a special handle. After starting, a welding current will be supplied to the ends of the saw, which will melt the metal in the area of ​​the future seam. The saw is supplied with current through the clamps. After the joint is heated, the movable clamp must be slightly displaced to form a weld bead. The seam is ready!

Make sure the surface of the electrodes is clean before welding. It is not necessary to clean all the electrodes, only the part that contacts the saw blade is sufficient. If you ignore this rule, the connection will be of poor quality. Contamination will break the resistance of the circuit.

Annealing

This is followed by annealing. It is necessary because, as a result of welding, the metal becomes too hard, which increases its fragility. Annealing helps to restore the canvas to its original state. After squeezing, the metal becomes plastic again, and its performance characteristics improve.

To perform annealing, you do not need to remove the blade from the clamp. Just set a different current supply mode. The main thing is to achieve a heating temperature of about 600 degrees. In expensive devices, there is a separate annealing function. But if you have a simple budget model, there are a few additional steps to take.

First of all, keep in mind that in addition to heating, you also need to cool the metal. And it is desirable to perform these operations one at a time. Press the current supply button and hold it until the heating temperature is displayed on the display. Then release and let the metal cool. To keep the canvas cool evenly, you can periodically press the button again, preventing the metal from quickly cooling. Cooling time takes an average of 5 minutes.

If your device does not have a display with an indication of the heating temperature, then you can focus on the color of the metal. Usually the canvas takes on a cherry hue when the required heating temperature is reached. Avoid heating metal to orange or yellow color. Sometimes it is necessary to perform annealing twice.

Repeated stripping

Visible beads may form on the web during annealing. They need to be removed by performing a second stripping. Now it is needed not for technical, but for aesthetic purposes. At the same time, you can correct the cavities between the teeth, giving them the correct geometric shape. Re-sanding can be done with any abrasive tool. Treat the metal so that the joints are almost invisible.

DIY garage press options

Homemade garage presses allow you to process a variety of products and materials under the influence of pressure. Structurally, the equipment consists of cylinders. In the garage, such a machine is useful for straightening or fastening various elements, as well as for bending sheets of metal or pressing cardboard.

An example of a homemade press

For private use, a capacity of 10-15 tons is sufficient. Most often, a bottle jack with a provided hand pump is used, which acts as the main structural element.

Here are some interesting options for homemade garage presses:

Option from scrap materials

DIY press from a jack: drawings and manufacturing options

There are two ways to create a homemade press from a jack:

• fix the device to the base of the bed to apply upward pressure;
• placing the jack close to the top of the bed for downward pressure.

Here are some useful blueprints for building your own home press:

Simple design with dimensions With a description of the elements Detailed drawing of the future press Example of a finished device

In order to choose the right model and dimensions of the future press, it is necessary to take into account several points related to the jack itself:

• its dimensions;
• the size of the working stroke of the rod;
• the thickness of the table;
• the height of the blanks for pressing.

See how to properly assemble a press from a jack with your own hands in the video: