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].
