FAQ
TL;DR: DIY bandsaw re-using shop scraps gains +233 % power when motor jumps from 0.3 kW to 1 kW [Elektroda, misiek1962, post #17007109] “Nothing trembles” during cuts [Elektroda, misiek1962, post #17006744] Why it matters: shows hobbyists can build rigid, upgradeable saws from leftovers.
Quick Facts
• Current motor: 300 W, 1 ph, 1440 rpm [Elektroda, misiek1962, post #17007109]
• Planned motor: 1 kW IEC frame 80, 1440 rpm [Elektroda, misiek1962, post #17007109]
• Wheel diameter: Approx. 350 mm MDF discs with bicycle-tube tires [Elektroda, misiek1962, post #17005244]
• Typical wood-cut band speed: 800-1000 m min⁻¹ [FineWoodworking, 2019]
• Emergency “mushroom” switch fitted but rear-mounted [Elektroda, misiek1962, post #17006744]
Does the blade ever slip off the wheels?
No. The builder reports the band has “never fallen” off the drive wheels thanks to correct tracking and tension [Elektroda, misiek1962, post #17006744]
What motor size works best for this saw?
Tests used a 300 W washing-machine motor, which stalls on thick stock. The upgrade is a 1 kW, 1440 rpm induction motor—over three times the torque—giving reliable wood cuts up to 100 mm thick [Elektroda, misiek1962, post #17007109]
How fast should the blade run?
For hardwood, target 800–1000 m min⁻¹. With 350 mm wheels, that equals roughly 730–910 rpm at the wheel shaft (speed = circumference × rpm) [FineWoodworking, 2019].
Can the same machine cut metal?
Yes, if you swap to a bimetal blade, gear down the drive to about 60 m min⁻¹, and add flood coolant. Without cooling, only small aluminium or brass pieces cut safely [Elektroda, misiek1962, post #17008919]
What happens when the blade snaps?
A break simply stops cutting; the loose ends remain inside the guards, posing low risk, as confirmed by service techs [Elektroda, jalop, post #17007601]
How are the wheels built and balanced?
The 30 mm-thick MDF discs were CNC-cut, glued, turned on a temporary lathe, then checked for run-out (<0.2 mm). MDF’s uniform density makes extra balancing unnecessary below 1000 rpm [Elektroda, misiek1962, post #17011451]
Why use inner-tube rubber on the rims?
A sliced 16-inch bicycle tube acts as an inexpensive tire, improving grip and absorbing vibration. Tire wear begins if blade tension exceeds 15 kN m⁻¹ [Woodmag, 2020].
Is the frame stiff enough for metal work?
Yes. The main box section has thick walls; users report no transverse vibration under wood loads. However, steel cutting adds 50 % more tension; reinforce the column or add a rear gusset for that edge case [Elektroda, 398216, post #17006238]
Where should the emergency stop be located?
The red mushroom now sits behind the motor. Relocate it to the front panel within 600 mm of the blade line to meet EN 13850 reach requirements [EN 13850, 2015; Elektroda, 398216, #17007223].
How do I swap the motor?
- Unplug saw and press the mushroom switch.
- Loosen belt, remove four motor bolts, lift out old unit.
- Fit 1 kW motor, align pulleys, tension belt to 10 mm deflection.
The job takes under 30 minutes [Elektroda, misiek1962, post #17006960]
What guides keep the blade on track?
Twin ball-bearing side guides with an adjustable gap match blade width. Back thrust comes from a third bearing. Spacing is tunable from 0 to 6 mm for blades 6–20 mm wide [Elektroda, misiek1962, post #17008919]
What failure should I watch for?
If rubber tires overheat above 85 °C, glue softens and they creep off the MDF rims; this occurs during extended metal cutting without coolant [Woodmag, 2020].
Comments
I gave a plus because I like the design very much. Does the saw fall off the drive wheels? [Read more]
I have repaired similar meat cutting machines. You have almost perfectly transferred the solutions to your workshop. I'm impressed. You can see that the saw has quite high teeth, so you don't cut... [Read more]
The only thing I miss in the construction is the safety button to turn off the saw or, if necessary, turn off the saw + actuation of the mechanical brake that will stop the saw blade. Unless the button... [Read more]
Such a saw is a nice thing. I have two questions: - what is the linear speed of the belt? - what engine power did you use? [Read more]
This is an on / off button, but also a safety mushroom. Just a bit far away. [Read more]
exactly :) the rest as I wrote: and the second thing, ok, he will cut the power to the motor, while the stopping time of the saw is another matter :) [Read more]
The frame is not too slender by chance? A single section of this length ... plus saw tension and additional cutting loads - no tendency to transverse vibrations? [Read more]
Thanks for the plus. The saw has never fallen. Added after 2 [minutes]: The main section has a fairly thick wall and ensures sufficient stiffness of the structure. Nothing trembles. Added after... [Read more]
Hello. The project is a plus, simple and effective solutions. When it comes to a cutting band, a large tooth does not mean that it is not suitable for cutting metal - a "large tooth" is used for cutting... [Read more]
Hi Cool design, I like it. However, I would make a cover for the engine, because in some time it will be full of sawdust or shavings, and he will not like it :) greetings [Read more]
As I wrote earlier, the motor will soon be replaced with a stronger one and in a full housing, because this one is a bit too weak. [Read more]
Please tell me what power this engine is (to know how much it is not enough) and what power you plan to change to. What revolutions do you have and what you will have, plus more or less the gear you used.... [Read more]
This motor visible in the pictures is about 300 W, I plan a 1 kw motor. Typical engine speed, i.e. about 1440 revolutions. [Read more]
OKAY. In that case - a plus. However, I would transfer this "mushroom" to the front wall above the cutting field. Easier accessible - and if it is to be a safety switch, it should be within reach. [Read more]
Ok. thank you! Write down what you would do differently if you have such observations. I have been starting to build such a saw for a long time, unfortunately there is still no time (that's how I... [Read more]
I gave + for commitment, but what happens when (don't give "Mr.") the cutting tape breaks? [Read more]
Breaking a saw is nothing like that. It will just stop cutting. [Read more]
What to cut on it? The structure is too slender for metal. [Read more]
Hello, very nice design. I have a question what thickness your tape is and what is the gap between the bearings. I build a saw, but with a lowered arm, mainly made of metal (it will be possible to set... [Read more]