Step by Step construction

instruction.
A complete bill of materials.
Exploded view and elevation
drawings.
How-to photos with instructive
captions.
Tips to help you complete the
project and become a better
woodworker.
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WJ128
Published in Woodworkers Journal The Complete
Woodworker: Time-Tested Projects and Professional
Techniques for Your Shop and Home
Americas leading woodworking authority
Strike Up the Bandsaw
WOODWORKER'S JOURNAL
2007 ALL RIGHTS RESERVED
22 SHOP PROJECTS
Thrust
bearing
adjustment
Thrust
bearing
Guide block
adjustment
Guide block
set screws
Guide
blocks
Blade
guard
Strike Up
the Bandsaw
B
andsaws are wonderfully quiet to operate and
dont pose the same kickback threat as table-
saws. Theyre ideal for making straight or curved
cuts, and the saw kerf creates much less airborne
dust. But if your bandsaw isnt tuned properly, youll
be the one singing the blues. Heres how to get your
saw adjusted and back on track.
A bandsaw is a tremendously versatile
and useful toolbut only if its running well.
Properly set up, it allows you to create poetry
out of wood. Out of adjustment it can cause
vocabulary usage that would impress the
most seasoned boatswains mate.
Tuning up your bandsaw is not a huge
undertaking. A couple of quick steps to
better align and control your blade will have
you cutting smoothly in just a few minutes.
Most modern bandsaws have a system of
thrust bearings (those little metal wheels that
the blades back edge bumps into) and guide
blocks that hold the blade in proper alignment.
Start by unplugging the saw, then loosen the
set screws that hold the guide blocks; back
them out so they no longer touch the blade.
Next, turn your attention to the thrust bearings,
backing them off the saw blade a 1/4" or so.
Center your saw blade on the drive and idle
wheels by rotating the top wheel by hand.
While you turn the wheel, use the tracking
control to shift the blade to the crown (top of
the arch) of whichever wheel adjusts the
tracking. Then adjust the thrust bearings for-
ward so they just barely touch the back edge
of the blade. Ideally, when the saw is running,
your blade will just tick the thrust bearings
until you start to cut; the pressure of that
action will drive the blade back to press
against the bearings fully.
Blocking Is the Key
While adjusted thrust bearings keep
the blade from moving front to back, guide
blocks control blade twisting and limit side-
to-side movement. If your guide blocks are
showing wear, replace them. Worn blocks
ruin good saw blades. The best replacements
are Cool Blocks, which are phenolic resin
guides imbedded with graphite. They are
superior to metal or wooden guide blocks in
preventing wear and overheating. The most
important thing to remember in adjusting the
guide blocks is that their position changes
with the size of the saw blade you are using.
The blocks must be set so they capture the
MAKE A BANDSAW BOX CRITTER
Figure 1: Glue the pattern (see the Pinup
Shop Drawings) onto stock that is thick
enough to create a box section in the animal.
Plan your cuts first so you dont cut yourself
into a corner. After cutting the outline of the
piece, cut out the center box section.
Figure 3: Put the side pieces away for now
and again reset the saw to the next depth
of cut. Draw lines to guide your cut as you
remove the waste from the box. Make the
opening as large as possible to allow for the
greatest access to the box after you glue
the sides back on .
Figure 2: Reset the saw for the depth of the
next cut. Carefully slice 1/4"-thick pieces off
of each side of the center box section. Hold
these cuts as straight and true as possible
as these pieces will become the sides of the
sliding box.
Figure 4: Glue the sides back onto the cen-
ter section. Sand the project smooth and
use a marker or 1/8" dowel of contrasting
color to make the eyes. Apply an oil or clear
finish. Flock the inside of the box section for
a finishing touch.
Tune up your bandsaw and then
test drive it on these northwoods
critter boxes.
sides of the saw blade, but they
should not engage the saw teeth
even when the blade is under
cutting pressure. You also need
a sharp blade of correct width to
match the job at hand. For resaw-
ing or long straight cutting opera-
tions, a wider blade is exactly what
you need. Tight curves call for
narrow 1/8" or 1/4" blades. Blade
tension is also important; start by
adjusting the tension to the blade
manufacturers specifications.
Increase tension further if the
blade deflects excessively.
Just these few steps will make
a huge difference in how well your
bandsaw cuts. Attention to detail
will provide for easier cutting and
a milder vocabulary.
Go Wild with Boxes!
Try out your newly tuned up
bandsaw on these three bandsaw
boxes. They are great gifts and fun
to make. Set up your bandsaw
with an 1/8" blade and use the full-
size patterns on the Pinup Shop
Drawings. Follow the steps shown
in the photos at right and enjoy
your new smooth-cutting bandsaw.
STRIKE UP THE BANDSAW 23
Pinup Shop Drawings
Bandsaw Box Critters
Make
the eyes with
a permanent
marker or a
1/4"-diameter hard-
wood dowel of
a complementary
color.
Sliding Box:
Line the inside
with fabric or
spray flocking.
Squirrel
(Side View)
Pinup Shop Drawings
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Pinup Shop Drawings