My new fabricated band saw!

I have wanted a big metal cutting band saw for a long time, but have always been shocked at the price. Recently I found a wood cutting band saw in the scrap yard and decided it would make a good starting point. After getting it back to my workshop, the first thing I realised was wood cutting band saws run fast, and metal cutting band saws run very slowly.

The existing machine had a 12" throat depth, so I extended the frame with some steel box section and decided on a through depth of 32". I then mounted 2 more wheels that I had pulled off a little Chinese 'lift up' band saw some time earlier with this project in mind.

Next, I had a band cut to length (14 TPI), as they are available in custom sizes. I then made (fabricated from sheet metal) the biggest pulley I could fit inside the case in an attempt to slow it down enough to cut metal.
It was still to fast, so I then relocated the motor and added another set of pulleys. This did the trick, it now runs at the correct speed for metal cutting.

The next job was to make a wheeled platform for it to sit on, and to bring the work table up to a decent height. If you look in the picture, you can see the original base of the machine sat on top of the fabricated trolley. The two doors with the locks in are the only original sheet metal. I added the locks, and fabricated 2 more doors and all the rest of the exterior sheet metal. I then relocated the cast iron cutting table, switch, and made various guards for the rear of the machine.

One other problem I came across was rigidity. Because I have extended the machine far beyond what the original frame was designed for, it was a bit flexible. I overcame this buy adding 1/2" plate steel up the spine, and across the back. I also added lots of little bracing bars inside. My machine is now very ridged, and f***ing heavy!

All the inner box section fabrication on this machine is crudely mig welded together from bits of scrap metal from around my workshop. I didn't really care what it looked like, because I thought once the panels are made, they will hide the mess. I did not use any new metal in the fabrication of this machine!

I can't tell you pleased I am with it's performance. It cuts sheet steel like paper, and chomps through 1/4" plate steel with ease, and even thicker at a slower rate. I can push really hard on the work piece without the band popping off.

I spray painted the various panels, and added a WoodsAutomotive sticker. My brother came into the workshop and thought I had bough it! HA HA HA fooled you..

Johnny