• Step by Step constructioninstruction.

• A complete bill of materials.

• Exploded view and elevationdrawings.

• How-to photos with instructivecaptions.

• Tips to help you complete theproject and become a betterwoodworker.

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WJ128

Published in Woodworker’s Journal “The CompleteWoodworker: Time-Tested Projects and ProfessionalTechniques for Your Shop and Home”

“America’s leading woodworking authority”™

Strike Up the Bandsaw

WOODWORKER'S JOURNAL ©2007 ALL RIGHTS RESERVED

22 SHOP PROJECTS

Thrust bearingadjustment

Thrustbearing

Guide blockadjustment

Guide blockset screws

Guideblocks

Bladeguard

Strike Up the BandsawBandsaws are wonderfully quiet to operate and

don’t pose the same kickback threat as table-

saws. They’re ideal for making straight or curved

cuts, and the saw kerf creates much less airborne

dust. But if your bandsaw isn’t tuned properly, you’ll

be the one singing the blues. Here’s how to get your

saw adjusted and back on track.

A bandsaw is a tremendously versatileand useful tool—but only if it’s running well.Properly set up, it allows you to create poetryout of wood. Out of adjustment it can causevocabulary usage that would impress themost seasoned boatswain’s mate.

Tuning up your bandsaw is not a hugeundertaking. A couple of quick steps to better align and control your blade will haveyou cutting smoothly in just a few minutes.

Most modern bandsaws have a system ofthrust bearings (those little metal wheels thatthe blade’s back edge bumps into) and guideblocks that hold the blade in proper alignment.Start by unplugging the saw, then loosen theset screws that hold the guide blocks; backthem 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 idlewheels by rotating the top wheel by hand.While you turn the wheel, use the trackingcontrol to shift the blade to the crown (top ofthe arch) of whichever wheel adjusts the tracking. Then adjust the thrust bearings for-ward so they just barely touch the back edgeof the blade. Ideally, when the saw is running,your blade will just tick the thrust bearings until you start to cut; the pressure of thataction will drive the blade back to pressagainst the bearings fully.

Blocking Is the KeyWhile adjusted thrust bearings keep

the blade from moving front to back, guideblocks control blade twisting and limit side-to-side movement. If your guide blocks areshowing wear, replace them. Worn blocksruin good saw blades. The best replacementsare Cool Blocks™, which are phenolic resinguides imbedded with graphite. They aresuperior to metal or wooden guide blocks inpreventing wear and overheating. The mostimportant thing to remember in adjusting theguide blocks is that their position changeswith 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 PinupShop Drawings) onto stock that is thickenough to create a box section in the animal.Plan your cuts first so you don’t “cut yourselfinto a corner”. After cutting the outline of thepiece, cut out the center box section.

Figure 3: Put the side pieces away for nowand again reset the saw to the next depthof cut. Draw lines to guide your cut as youremove the waste from the box. Make theopening as large as possible to allow for thegreatest access to the box after you gluethe sides back on .

Figure 2: Reset the saw for the depth of thenext cut. Carefully slice 1/4"-thick pieces offof each side of the center box section. Holdthese cuts as straight and true as possibleas these pieces will become the sides of thesliding box.

Figure 4: Glue the sides back onto the cen-ter section. Sand the project smooth anduse a marker or 1/8" dowel of contrastingcolor to make the eyes. Apply an oil or clearfinish. Flock the inside of the box section fora finishing touch.

Tune up your bandsaw and thentest drive it on these northwoodscritter boxes.

sides of the saw blade, but theyshould not engage the saw teetheven when the blade is under cutting pressure. You also need a sharp blade of correct width tomatch the job at hand. For resaw-ing or long straight cutting opera-tions, a wider blade is exactly whatyou need. Tight curves call for narrow 1/8" or 1/4" blades. Bladetension is also important; start byadjusting the tension to the blademanufacturer’s specifications.Increase tension further if the blade deflects excessively.

Just these few steps will makea huge difference in how well yourbandsaw cuts. Attention to detailwill provide for easier cutting and a milder vocabulary.

Go Wild with Boxes!Try out your newly tuned up

bandsaw on these three bandsawboxes. They are great gifts and funto make. Set up your bandsawwith an 1/8" blade and use the full-size patterns on the Pinup ShopDrawings. Follow the steps shownin the photos at right and enjoyyour new smooth-cutting bandsaw.

STRIKE UP THE BANDSAW 23

Pinup Shop Drawings

Bandsaw Box Critters

Makethe eyes with

a permanentmarker or a

1/4"-diameter hard-wood dowel of

a complementarycolor.

Sliding Box:Line the insidewith fabric orspray flocking.

Squirrel(Side View)

Pinup Shop Drawings

Band

saw

Box

Cri

tter

s

2.

Cut

the

bac

k si

de n

ext,

right

up

to t

he t

ail.

Bac

k ou

tal

ong

the

saw

ker

f.

Don

’t fo

rget

to

finis

h th

ein

side

of

the

box

befo

resp

rayi

ng t

he f

iber

s.3

. R

e-en

ter

your

firs

tcu

t to

com

plet

e th

ebo

x an

d sl

ide

the

box

sect

ion

out

ofth

e bo

dy.

5/16

"pr

edril

led

hole

Lo

on

(Sid

e V

iew

)

1.

Cut

und

er t

he b

eak

into

the

pred

rille

d ho

le.

Spi

n th

e bi

rdar

ound

and

ret

urn

thro

ugh

the

kerf

you

just

cut

.

Bandsaw Box Critt

ersNote: S

elect or g

lue

up stock

for y

our crit-

ters that is

thick

enough to cr

eate

suffic

ient room in

side

the box for s

torage.

Porcupine

(Side V

iew)

Pinup Shop Drawings