his month's "how to buy" topic is band saws. Depending on what kind of woodworking you normally do, band saws can be essential to the shop or a perfect accessory to the table saw.
There are two common styles of band saws, the three wheel and the two wheel. After this it is mainly a matter of size. Three wheel band saws give you a greater throat depth than a two wheel having the same blade length but they have other problems, which take away from any cutting advantage. Two wheels are much easier to align properly and keep aligned during use than three. The thinner blades also will break much easier with three wheels because of the extra stress created by smaller wheels. All in all, there are very few three wheel band saws, which are worth the money and hassle they create. There was a time when there were many on the market, but these days they are rare except at garage sales. If you need the extra throat depth then buy a larger two wheel machine. Just as an example, years ago I was using a three wheel band saw and it took me almost half an hour to get the blade to track properly only to find when I put it under load the tracking went off again. From here on I'm only going to talk about the two wheel band saws.
The frame construction is the first thing to look at. Smaller bench top band saws can be pressed metal, plastic resin, steel or cast iron. Larger band saws will be either cast iron or steel. The pressed metal and plastic resin are not as rigid as steel or cast and these saws are definitely meant for light duty hobby and craft work. You are much better off to get one that has a steel or cast iron frame. They will last longer, run smoother and the blades will track better. Larger band saws all come with cast iron or steel frames so you do not have to worry about the rigidity. Each type of frame has its advantages and disadvantages. Steel frames are the most rigid and therefore more stable and smoother running, but they are also more expensive. Cast iron frames are cheaper and often allow you to increase the height capacity using a riser, but having cast parts they can crack and fracture through use. In most home shop applications this is not a large issue but it depends on the amount of use.
Motor size can range from 1/6HP to 1/3HP for bench top and from 1/2HP upward to 3HP or larger on big industrial machines. The smaller the motor the harder it has to work. If you mainly work on smaller crafts or model construction, the smaller bench tops are fine, but in the long run try and go with one, which has 1/4HP or larger. If you build furniture, cabinets or larger projects go with a floor model with at least a 3/4HP motor. The 1/2HP models just don't have enough power for heavier cutting. If you want to cut metal, then make sure the machine has slower speeds, down to less than 200 rpm instead of the approximate 3000 rpm for woodcutting.
Make sure the table tilt and adjustment works smoothly and does not bind anywhere. Tilt it to the full 45 degrees and look underneath to make sure nothing is interfering with the blade. If the saw does not come with a fence, see if the table to drilled and or tapped for a fence rail. The quality of band saw fences is wide, so have a good look at it. If you really like the saw but the fence is garbage all is not lost. If nothing can be done with the existing one you can make your own which can be just as stable and accurate as anything available. The average table size is about 143 x 143. Many woodworkers find this a little small so you can buy or build a larger auxiliary table to give you a greater work surface.
There is not a great deal of difference between an open and closed stand. Open stands are just as stable and in some cases more so, but they do allow your motor to be out in the open where dust can get into it. If you have an open stand make sure you blow the dust out of the motor on a regular basis. Closed stands keep the motor cleaner, but not totally dust free, plus they offer storage space for wrenches, hex keys, manual and accessories.
The blade on a band saw is held in place by either guide blocks or bearings. Bearings run cooler, smoother and quieter than blocks. The majority of saws have guide blocks but there are conversion kits available or blocks made out of resins, which run cooler and smoother than the steel factory ones supplied. If is worth using either option since you blades will last longer and the noise level will almost be cut in half.
Most machines these days have dust ports of some sort and they are important for the same reasons; cleaner air, safer shop environment, cleaner longer lasting machine.
If you are interested in doing a lot of resawing, look into an actual resaw band saw. Most band saws will go up to ¾" or 13 wide blades and although they can resaw the odd piece, they are not designed for continuous long-term use like this. Resaw band saws have a much more powerful motor and use blades about 33 wide, some are even carbide tipped. You need the wider blades to maintain a straight even cut throughout the entire depth of material. Try and determine how much resawing you will want to do. If a standard band saw will be okay, just do not push it too hard when cutting material 33 and thicker and use as wide a blade as possible.
Make sure the blade tension; tracking, height and table adjustments are all convenient, easy to use and secure. You do not want to be constantly adjusting and tuning the machine so make sure there are no obvious problems. Any sloppy connections or adjustments could mean problems in tracking or stability.
Just a quick work about two common accessories. If your band saw does not come with a lamp, it is a good idea to buy one or set something up. Because of how you normally stand at the saw, your shadow naturally falls right across the table and blade. This can be very annoying if you are trying to make intricate and precise cuts, so a lamp is worth it. The second is a circle cutting attachment. This is a pet peeve of mine. There are some on the market, but they usually have a very small capacity. They are fine if you are making toys or smaller projects but not for even a medium sized tabletop. This is one attachment, which is easy to make yourself. Some plywood for the top, a 2×2 or 2×4 for the leg support and some clamps and you are in business. You can make it as large as you need, providing lots of work support and you can cut small circles on it as well.
Band Saw Check List
-Size. 83 to 243 throat and 33 to 133 height capacity. Make sure it will have enough depth and height capacity to do what you want it to. You need to take into account space, capacity and what you want to cut. Band saw sizes can be advertised either by the diameter of the wheels or by the cutting capacity, so be careful when you compare.
-What is the frame made of and is it solid and stable.
-Motor - Check the horsepower and amps. You'll need both when comparing. For bench top saws get at least 1/4 HP, better 1/3HP and for general shop use, a floor model with 3/4HP, or even better 1HP.
-Check that the wheels are balanced. You can tell by looking for circular drill marks where material has been removed to equal the weight around the rim.
-Table should tilt to 45 degrees right and if it tilts to the left as well it is a bonus. What size mitre slot and what kind on mitre gauge.
-Does it have guide blocks or bearings and if blocks is there bearing kits or resin blocks to replace the original steel blocks.
-What size dust port does it have and does it match your system or do you need an adapter.
-Where is the power switch and is it easy to reach? Switches in awkward places can be a safety hazard.
-Where is it made and where do you get parts & service? There are some excellent offshore machines out there but you have to be careful because there are also some bad ones. Check the brand and the company you are buying from and find out exactly where you can get servicing done.
Good luck. You are the one paying for it and using it, so find out as much as you can before you make the purchase so you wont have any regrets. And remember, no loose clothing and no jewelry, wear short sleeves, safety glasses and hearing protection.
Thomas is a writer for Western Tool - a premium online retailer of tools including saw blades, band saw blades, circular saw blades and more.
