How to Make a Band Saw Pulleys
With the help of a band saw, it is possible to saw various kinds of materials having impressive volumes. The cost of this tool is very high, so it is much easier to make it yourself. About the features and stages of manufacturing a homemade band saw, we will consider further.
The device of the band saw and the principle of its operation
A band saw is a device consisting of a blade and a cutting gear located on it, mounted on the surface of the pulleys. During the rotation of this element of the saw, sawing of logs or metal products large in diameter occurs, depending on the functional purpose of the tool.
The price for a band saw is quite high, so its independent production will cost several times cheaper. Before starting work, we recommend that you familiarize yourself with the device and the principle of operation of this tool.
Depending on the teeth mounted on the saw, it can be of two types. First option. A narrow saw, the teeth of the cutting mechanism of which are not more than 5 cm. Wide saws imply the use of mechanisms with teeth of more than 8 cm.
In addition, the quality and speed of the band saw also depends on the shape of the teeth located on the cutting mechanism. The maximum tooth height is twenty percent of the width of the platform. Otherwise, the canvas will not withstand the load and simply breaks.
In addition, the speed and quality of the saw depends on the correct location of the teeth and the interval between them and the work platform. With an insufficient interval, sawdust will begin to accumulate between the saw and lead to its breakdown. Therefore, the minimum blade width on a band saw is twenty-five centimeters, and the minimum tooth size is five centimeters.
Wide saws are more powerful. In addition, in their use there is practically no problem of clogging sawdust between the timber and the working surface. They are not prone to breakage or the appearance of cracks on the surface of the cutting mechanisms.
In order to prevent the saw from jamming during work, a work on the separation of the teeth should be carried out. In this case, the first tooth is located with a slope to the left, the second. To the right, and the third. Straight. This order is repeated constantly. Thus, the first and second teeth perform the function of cutting, and the third, is engaged in cleaning the surface of sawdust. In this case, each of the teeth helps to cleanse one third of sawdust. However, the performance of these tools is slightly lower, since every third tooth is not involved in the sawing process. Compared to saws that have high teeth, where each of them works as intended, and sawdust is removed without the participation of teeth.
In the production of band saws, some tricks are used, with which it is possible to achieve high performance saws. To increase the quality of work of a saw with low teeth, the width of the working blade increases. In this case, it is possible to raise the teeth to a great height. The teeth are subjected to special grinding, after which the productivity of their work is one hundred percent. Sawdust is carried out automatically, and the teeth do not need additional wiring.
How to make a do-it-yourself band saw
The process of making a band saw depends on many factors, such as the device’s engine, its size, saw bands and additional workpieces. To work, first of all, you need an induction motor, it can be purchased on the market. This version of the saw, the manufacturing instruction of which is presented below, is made almost of wood and has the following characteristics:
- Height 120 cm, width and depth 90 cm;
- Wheel diameter is 40 cm;
- Width and depth of the workplace. 51×47;
- The table is able to tilt at an angle of 45 degrees;
- Total weight. About 50 kg;
- Workpieces with a maximum thickness of 26 cm;
- Web length. 2.66 m.
Before starting work, drawings of the band saw should be made. The main and very important element of this tool is the work surface, which should be made first.
For its manufacture, wood, pine, 2 cm thick was used. Please note that the use of plywood, chipboard, furniture board or MDF for the manufacture of this element of the saw. Unacceptable.
The shape of the frame resembles beech C, in its upper part there is a mechanism on which the wheel is stretched, and on the lower part two legs are fixed connecting it to the base. The frame contains six layers and overlays. In order to increase its rigidity, diagonal parts are also used. All elements can be glued in stages. At the same time, rigidity of their fixation and perpendicularity of location are carefully checked. The frame is equipped without foundation, it is mounted later, upon completion of work on the saw. After making the frame, it is ground and varnished or painted.
The process of making a frame of wood is as follows:
- In order to determine the shape of the element should be interconnected materials for the first layer;
- In the process of gluing subsequent layers, the lack of clamps is compensated with screws;
- Guides are installed on the finished frame, the impeller will be fixed on them;
- For inserts under the wheel, special grooves should be arranged;
- Further, a mechanism is established that is responsible for the tension of the paintings;
- In order to glue the wheel, three plywood circles are used;
- Engine sheave boring is carried out prior to installation.
Further work on the manufacture of a band saw with his own hands is associated with the arrangement of the mounting block for the upper wheel. This element is located vertically and provides tension between the paintings. An oak profile is used to form the guide groove. A block is called a rectangular frame, into which movable holders and the upper wheel are installed. Oak is used for the manufacture of the frame, because of its strength. In order to further strengthen the corner joints, inserts are used. After gluing the frame, grooves are cut inside it.
The frame moves along the grooves smoothly and easily. In its upper part, a special element is mounted in the form of a bolt, which is responsible for transporting the frame on the canvas and for its tension. In the form of a holder, a block is used that has a certain hole, a screw is installed on its surface that regulates the inclination of the wheels. The holder is fixed on the frame surface using self-tapping screws, and additional elevators help make it movable. Under the screw, a steel lining is mounted to ensure its rigidity.
To fix the shaft on the surface of the holder, a self-tapping screw is used. Using three plates made of oak, it is possible to achieve a springy effect on the canvas.
The next no less important stage involves the work on the wheels of a bandsaw manual. The diameter of the wheels is about 40 cm. For their manufacture, MDF or plywood is used. The thickness of the wheels is about three centimeters. For example, using plywood, you should make three circles, which are subsequently glued together.
Pay special attention to the central part of the wheel, use a milling machine to cut workpieces under it. A hole with a diameter of about 0.6 mm is drilled in the central part of the wheel. At the same time, a milling compass is installed inside it. Further on this hole the rest of the workpiece are combined with each other.
The allowances for cutting circles are up to one millimeter. In the absence of experience with locksmith tools, order bearings and shafts for them from specialists or make them yourself if you have the necessary equipment.
One side of the part is distinguished by the presence of a limiter, and the second. Internal thread. In order to make flanges, plywood is used. In each of the four wheels, one hole for dowels is drilled, the diameter of the hole is 0.06 cm. The main components of the flanges are its outer part, the thickness of which is 1.5 cm, the bearing and the inner part, about one centimeter thick. The diameter of the wheel is slightly larger than the diameter of the shaft.
A very important step is the process of drilling holes for bearings, their diameter is 5.2 cm. For work, you will need a circular saw, and for pressing bearings into the holes, use a mallet.
Before fixing the flanges on the surface of the wheel, a holder is mounted on the lower shaft. It has the shape of a wooden block fixed on the bottom of the frame. Technological holes are drilled in each of the wheels, into which clamps are installed. After finishing work on the wheel, it is fixed on the shaft. Make sure that the wheel does not run when it rotates. In order to adjust the wheel and form the desired profile, you should connect the wheel and the engine.
For these purposes, the use of a temporary plywood pulley mounted on the wheel with self-tapping screws is recommended. To undercut the motor pulley, you can use the motor directly, which is then connected to the temporary pulley using a belt.
The wheel should be clearly fixed, and a wooden beam is used as a stop mechanism. In order to avoid slipping of the tape from the surface of the wheel, it is given a barrel-shaped shape. At the same time, on each side there is a bevel of about five degrees.
Do-it-yourself band saw instruction:
1. After manufacturing all the parts, the flanges are mounted on the wheel, their fixation is carried out by glue.
2. The mounting unit on the lower shaft is also a holding mechanism.
3. The edge of the wheel should not be flat, but sharpened by 4-7 degrees. The following is the installation process for all guides and bearings. A rubber camera is mounted on the wheel.
4. The desktop is installed in the same plane with the inclined mechanism.
After manufacturing two wheels, a pulley of a standard drive type is mounted on one. Its size and thickness depends on the belt used.
The following is the process of balancing the wheels. For these purposes, the presence of bearings will be required, which will become the supporting mechanisms for the saw blades. After fixing the horizontal time axis, the wheel is installed and the level of its rotation is checked. With the help of a special drill, grooves are made in the lower part of the wheel from the outside, so the wheel will rotate only in a certain position. Wheel setting is completed, they are covered with varnish.
In order to protect the surface of the wheels from destruction due to friction and pressure, rubber can be put on their surface, for example, from a children’s bicycle. In addition, the noise level emitted by the saw during operation will be significantly lower.
The following is the fixation of the wheels on the surface of the frame. First, a wheel is mounted on top. A washer is put on the shaft surface, which is based on fluoroplastic. To fix the wheel, a bolt and a thick washer are screwed into the shaft end. Using the adjusting bolt, the wheel is mounted in a parallel position to the frame.
To fix the lower wheel unit, use clamps and install the wheel located below. The ruler will help to position the wheels in the same plane. After that, fixation of the block, on the lower shaft follows. Check how the wheels rotate manually, check their fixation again, and then start the engine. The tape should be located in the middle of the wheel, the movements should be smooth and symmetrical.
If vibration and additional sounds are present, turn off the saw and check the parallel alignment of the wheels.
Next, install guides on the saw blade. To make them, it is best to use wood. In addition, a protective system in the form of a rectangular pipe made of duralumin should be made. To fix the protection on the bus, use self-tapping screws. When setting the tire, be careful as there are skews. Unacceptable. The tire is fixed to the surface of the frame using grooved joints. When marking the canvas should be tightly stretched. Following is the fixation of the tire.
Further actions involve the manufacture of a work surface for a band saw. For these purposes, you can use chipboard with inserts from MDF. In addition, under the saw must be made stand, the dimensions of which depend on the size of the tool itself.
Installation of electrical elements to ensure the operability of the mechanism is done at the end. There is also the option of mounting the illumination of the working area, for these purposes, a lamp is required. In order to ensure parallelism of the saw stop, an eccentric was used.