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Sunday, 1 April 2007

Bandsaw Blade Jig And Repair

Bandsaw Blade Jig
25mm Square tubing approximately 150mm long
25mm flat steel approximately 150mm long
4 x ¼” diameter bolts approximately 20-25mm long
¼” tap for creating a thread

Step 1
Cut a notch in the tubing with a saw or angle grinder.

Step 2
Do the same to the flat steel.

Step 3
Clamp the two pieces together and drill 4 holes for the bolts to attach to. See the recommended size from your tap set to allow a ¼” thread to be created. You can slightly oversize the flat steel to allow the bolts to fit through. This will not be threaded.

Step 4
Tap the thread in the square tube and assemble.

This is now your bandsaw blade jig.

Repairing Bandsaw blades
I have found that I use a lot of bandsaw blades over time (I make toys and stuff) and found that with a little care you can repair broken blades yourself with ease.

I also have access to some old blades from a woodwork place. These I take and cut to fit my own machine and thus have a decent supply readily available.

Bandsaw blade jig (see elsewhere)
Gas welder for brazing
Grinding tool or file
Brass brazing rod

Step 1
Bevel both ends of the blade to form a scarf joint.

Step 2
Clamp the blade in your bandsaw blade jig so the ends overlap.

Step 3
Apply heat and melt the brass brazing rod into the bandsaw blade joint.

Step 4
When cool grind the joint smooth. Don’t forget to do both sides of the blade.

Ensure that the joint is smooth.

I usually save up half a dozen blades to do and make a morning of it whilst listening to the football or cricket on the radio in my workshop.

Very therapeutic 8-)


Anonymous said...

Hey, I like your self made tool! I was just wondering about how brass held up compared to the silver sold in commercial kits? I've been shopping around for a kit and they all come with this silver ribbon. Where would I get these brass brazing rods? Is this available where welding supplies are sold? Will brass work on stainless steel blades?

Lots of questions! Hope I'm not too much trouble. :-)

Doc said...

G'day Pierre (bonjour, mon ami)

The brass seemed to hold up well but then I never had the silver ones to make a comparison. I picked up the rods from my local hardware shop in the welding section but you might find them in a good plumbers shop because (I believe) they often use brass to join copper pipes together.

I don't know whether it works with SS blades 'coz I never had an SS blade.

Since this article was published (2007) I now have a much bigger bandsaw and have never broken a blade so I am answering this comment relying on my memory - not always a good idea LOL.

Bon chance!

Doc ;-)

Tom Francis said...

Thank you for posting this very helpful information. I will make one of these jigs ASAP!

The only thing I will change is to use silver solder (like the kits they sell at woodworking suppliers) to join my blade. I have used it before and it works well, and I've not had it ever break.

Thanks again!

Tom Francis said...


I do have one question for you. What size opening did you use for your jig?

Thanks in advance for your reply!

Doc said...

Hi Tom

Thanks for dropping in.

The gap is arbitrary. I used one of approx 25mm. No reason, really.

The gap is there to provide the space needed for the flame to heat the blade, if that makes sense.

As for the rods, as I mentioned to Pierre above, I did not have silver solder handy when I did this article (2007-ish) but you probably have nothing to loose anyway by trying.


Doc ;-)

lasantha said...

that is more helpfull to me.thak u sir. to your kindly advice...