A band saw is a power tool that uses a long, continuous blade to make precise cuts in various materials, primarily wood and metal. The blade loops around two or more wheels, creating a constant cutting motion. Band saws excel at making curved cuts and ripping thicker stock, tasks that can be challenging with other power tools. This guide will walk you through everything you need to know about using a band saw, from understanding its components to mastering advanced techniques.
Band Saw Types
Band saws come in several varieties to suit different needs:
- Benchtop: Smaller and more portable, perfect for home workshops or job sites
- Horizontal: Used primarily for cutting large stock or metal pipes
- Metal-cutting: Specifically designed for cutting metal with slower blade speeds
- Stationary: Large, floor-standing models ideal for professional workshops
- Vertical: The most common type, with the blade running vertically
Key Components of a Band Saw
Understanding the main parts of a band saw is essential for proper use and maintenance:
- Blade: The continuous cutting element that does the work
- Fence: Helps maintain straight cuts
- Guides: Keep the blade aligned and prevent wobbling
- Table: Supports the workpiece during cutting
- Wheels: Upper and lower wheels that guide and tension the blade
Choosing the Right Size and Blade for Your Band Saw
Band saws are typically categorized by their throat size, which is the distance between the blade and the vertical frame of the saw. When choosing a size, consider the types of projects you’ll be working on and the space available in your workshop. Here are some common sizes:
- 10-inch: Suitable for small, benchtop models
- 14-inch: The most popular size for home workshops, offering a good balance of capacity and affordability
- 18-inch and larger: Ideal for professional shops or those working with large stock
Selecting the right blade helps you achieve clean, efficient cuts. Blades vary in width and tooth count. Narrow blades are best for cutting tight curves, while wide blades are ideal for straight cuts and resawing. More teeth per inch (TPI) result in smoother cuts, while fewer TPI allows for faster, rougher cuts. A good general-purpose blade is typically 1/2-inch wide and has three teeth per inch, suitable for a variety of wood cuts.
Setting Up Your Band Saw
Take your time to set your band saw up correctly for safe and accurate cutting. This section will guide you through installing the blade, adjusting the guides, and aligning the table.
Installing the Blade
Follow these steps to install a band saw blade:
- Unplug the saw and open the cabinet.
- Release the blade tensioner.
- Loop the blade onto the bottom wheel, then roll it onto the top wheel.
- Ensure the teeth face down toward the table.
- Tighten the tensioner just enough to remove slack.
- Rotate the top wheel by hand and adjust the tracking knob (usually at the back of the top wheel) until the blade centers on the wheels.
- Next, follow the manufacturer’s directions for correctly tensioning the blade. The amount of tension applied will depend on the blade’s width.
Adjusting the Guides
To track true and keep the blades on the wheels, band saws rely on guides above and below the table. To begin, make sure none of the guides are touching the blade. Then, follow these steps
- Working from the top first, loosen the blade’s locking bolt.
- Adjust the thrust bearing to be about a business card’s thickness from the blade.
- Next, move on to the guide blocks at the side of the blade.
- Set the side guide blocks about a paper’s thickness from the blade.
- Align the guide blocks with the gullets between the blade teeth.
- Repeat the process for the lower guides below the table.
Aligning the Table
To ensure square cuts, follow these steps:
- Loosen the table’s locking knobs below the table.
- Use a combination square to set the table perpendicular to the blade.
- Tighten the locking knobs securely.
Safety Precautions When Using a Band Saw
Safety should always be your top priority when working with power tools. Always wear safety gear when operating a band saw, including safety glasses or goggles, hearing protection, a dust mask, and close-fitting clothing. Avoid loose sleeves or jewelry.
Maintain a safe work environment by ensuring proper lighting, keeping the floor clear of debris, and using a dust collection system. Also, keep the work area clutter-free.
Be wary of these potential hazards:
- Cutting a material that’s too small to safely handle
- Forcing material through the cut
- Leaving the saw running unattended
- Reaching across the blade while it’s moving
- Removing safety guards
Mastering Basic Cutting Techniques
Once you’ve set up your band saw and understand safety precautions, it’s time to learn basic cutting techniques. This section covers straight cuts, curved cuts, and ripping and resawing.
Cutting Straight Lines
To make straight cuts with your band saw, follow these tips:
- Before making any cuts, set the blade guard to be about 1/2-inch above the stock.
- Each time you change the blade you’ll have to verify that it cuts parallel to the fence.
- Grab a 2-foot-long piece of scrap with a line drawn down its middle parallel to one edge.
- Cut that line by eye as well as you can.
- When the scrap is aligned correctly with the blade, you’ll feel that you’re cutting straight without having to make big adjustments.
- Stop. While holding the workpiece to the table, turn off the saw.
- When the blade stops moving, mark the table with a pencil along the edge of the scrap piece.
- Loosen the bolts holding the fence, set the fence to that line, and retighten the bolts. That’s the fence setting parallel with that blade. You can move the fence normally to vary the width of your cut as needed. If your saw doesn’t have a fence, you can buy aftermarket ones or simply clamp a straight piece of wood to the table.
Making Curved Cuts
Start by matching the blade to the curve. Then, follow these tips:
- Choose a blade width appropriate for your curve radius. For very tight curves, use a narrower blade. However, too narrow a blade can make it hard to cut a shallower curve and leave a fair surface.
- When cutting, keep up a light, steady feed rate on the workpiece, turning it along the blade as needed. Stopping to readjust your approach won’t make a smooth cut.
- Draw your curve on the workpiece. It’s best to try to cut just to the line. Staying outside it a little is fine, as you can finish the curve by sanding it. If you end up inside the line, that’s harder to fix.
- For tight cuts, it helps to make a series of relief cuts first (cuts that go “perpendicular” to the curve) and right up to the layout. As you cut the curve and pass through the relief cuts, the scrap falls away, giving the back of the blade room to move.
Ripping and Resawing
Ripping involves cutting along the grain, while resawing cuts boards into thinner pieces. Use a wider blade for these operations, and set up a tall fence for support. Feed the workpiece slowly and steadily. Use push sticks or featherboards for safety.
Advanced Band Saw Techniques
As you become more comfortable with your band saw, you can explore advanced techniques.
Creating Joints
While band saws aren’t typically used for joinery, they can create some joints. With practice and precision, you can make various joints using a band saw, expanding your woodworking skills.
- Dovetail joints: With practice, you can cut the pins and tails of dovetails.
- Lap joints: Cut halfway through two pieces and join them.
- Tenons: Use the band saw to rough out tenons before the final fitting.
Cutting Circles and Patterns
For perfect circles, use this technique:
- Create a circular cutting jig with a pivot point.
- Attach your workpiece to the jig.
- Rotate the workpiece around the pivot as you cut.
Follow these steps for more intricate patterns:
- Use a narrow blade for tight curves.
- Practice on scrap material first.
- Take your time and make relief cuts as needed.
Working With Different Materials
Band saws can cut more than just wood. Each material requires specific blades and techniques to ensure clean, precise cuts. Always adjust your technique and blade choice to suit the material. This versatility makes the band saw a valuable tool for projects beyond woodworking.
Here’s how to cut other materials with a band saw:
- Foam: A coarse blade works best for clean cuts in foam.
- Metal: Use a metal-cutting blade and slower speeds.
- Plastic: Use a fine-toothed blade to prevent melting.
Band Saws: Maintenance and Troubleshooting
Regular maintenance keeps your band saw running smoothly. Clean sawdust from the wheels and guides after each use, and lubricate moving parts according to the manufacturer’s instructions. Check for wear on rubber tires and replace them if necessary.
You should also replace blades when they become dull or damaged. Tension new blades according to the saw’s specifications. Allow new blades to run for a few minutes.
If your blade is wandering, check guide alignment and tension. For excessive vibration, ensure the blade is tracking correctly. If your cuts are of poor quality, verify the blade is sharp and that you’re using the right blade for the material.
