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It was a tight squeeze getting the slightly larger motor on the mount. I initially installed a salvaged ¼ hp motor, less power than the 1/3-hp to 2-hp range Wandel recommends, and it stalled sometimes, so I shopped around online and found a 1-1/2-hp motor on sale. The bottom drawer holds blades and accessories. The top drawer built into the base catches sawdust.Īfter the motor is installed and the wheels on the frame are running true with a blade in place, now comes perhaps the most satisfying part of the whole project: turning the saw on and using it to cut the curved parts for the saw’s own tilting table’s trunnions. It is trued and gets its V-belt groove cut while the temporary pulley turns the wheel. The lower wheel includes a drive pulley made of 3/4” birch plywood. With each wheel slipped in turn over a stationary axle, a temporary pulley from junk plywood is used to spin it for shaping and truing. The instructions suggest using a mallet to drive the bearings in place on one of Wandel’s videos he uses a vise as a press. The holes for the bearings are drilled slightly undersized, and big C-clamps and sacrificial blocks, along with a bench vise, press the bearings into the very tight holes. The higher quality plywood is required to provide a tight and long-lasting connection to the bearings. Flanges made of ¾” Baltic-birch plywood glued on either side of the wheels capture the bearings. The wheels are made of two layers of 3/4″ fir plywood. The four holes in each wheel are finger holds for turning the wheels when installing a blade. The wheels are made of plywood and have inner-tube tires. The multiple glue-ups will require some creative clamping, weights, and occasional screws, which must be removed to avoid accidentally drilling or cutting into them later. After the first layer is carefully made flat and square, with all parts edge glued on a dead-flat surface, all the subsequent layers easily fall into line on top. The frame is made of eight laminations of interlocking 3/4″ softwood boards. The 16″ saw uses 105″ blades-the same as used by commercial 14” bandsaws with risers-available at most woodworking outlets.Ī SketchUp view of the frame shows the laminates that go into it. Wandel, in a video about the cost of his tools, noted that salvaging a motor-his 1/2-hp motor was from a furnace-is what makes the homebuilt bandsaw a good bargain. The tires are made from bicycle inner tubes! The average cost for everything, including the motor, is between $200 and $500. The bulk of the material needed is wood, and Wandel encourages using shop scraps and reclaimed lumber, so builders will probably find the only significant costs to be bearings, shafts, blade, drive belt, bolts/screws, and a motor. Turning, truing, and balancing the plywood wheels and the pulley, with their own bearings on stationary axles, allows for reliable precision with no special tools. The laminated softwood frame is very stiff, lightweight, easy to build, and cheap-I built mine largely with scrap lumber. The most elegant aspects of Wandel’s bandsaw design are the frame and wheels. With SketchUp, all of the assemblies can be exploded and each part can be viewed from any angle. The plans also refer the reader to Wandel’s website with exhaustive articles and photos about this project, and to 19 bandsaw-related videos on his YouTube channel.
#Gear template generator matthias wandel free#
Sketchup is a free CAD program that allows you to see the complete bandsaw and every part from any angle.
#Gear template generator matthias wandel pdf#
The digital plans for the bandsaw include thorough instructions with over 120 photographs, complete materials and cut lists, PDF print-ready full-sized templates of key parts, and Sketchup 3D digital models.
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The thrust bearing meets the blade with it edge, rather than its face, as typical in commercial bandsaws. The blade guides are hardwood and have the advantage that they’ll never dull the blade teeth. It’s up and running and someday, I suppose, I’ll get to the box joints. The jig uses three wood gears, which require a bandsaw to cut them I didn’t have a bandsaw, so I decided to build Wandel’s 16” bandsaw. If you somehow haven’t stumbled onto his videos yet, you’ll want to pack for a long visit. My research on the web led me to a gear-driven box-joint jig created by Matthias Wandel, a Canadian engineer, woodworker, and YouTuber. My woodworking began with house repairs with one project leading to another, and one required that I cut box joints. The plans include a dust-collecting cabinet that supports the bandsaw at a working height.