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Metal Band Saw: Horizontal Saw on a Welded Steel Frame
Martin

Created by

Martin

23. October 2026NO
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Metal Band Saw: Horizontal Saw on a Welded Steel Frame

Curtis Eccardt's horizontal power band saw (Emerson Electric, US 4,364,294, 1982), built from welded steel channel and tube instead of iron castings to cut its cost. The saw head swings down on trunnions over the bed; a hydraulic cylinder with a valve sets how fast it feeds, a spring counterbalances it, and a spring tensioner shows the blade tension on a scale. Two guides with rollers twist the blade's lower run 90° so its teeth face down into the work, and carbide inserts hold it there. The patent gives no sizes, speeds or ratings; the welder and wrenches are ours. The picture: the patent's Fig. 1.
Advanced
4 days

Instructions

1

Weld the bed

Stand two steel channels (9a, 9b) parallel, webs upright and flanges facing in, and weld gussets (15) between their webs. Bolt a bed plate (17) across the top flanges as the work surface. Ours: MIG welder, drill press for the bolt holes.

Materials for this step:

Steel Channel SectionSteel Channel Section2 pieces
Mild Steel PlateMild Steel Plate1 piece
Hex Bolt - Grade 8.8Hex Bolt - Grade 8.81 piece

Tools needed:

MIG WelderMIG Welder
Drill PressDrill Press
Adjustable WrenchAdjustable Wrench
2

Weld and bolt on the legs

Weld formed sheet-steel legs onto horizontal floor members to make front and rear leg weldments (19, 21), and bolt them under the bed.

Materials for this step:

Steel SheetSteel Sheet1 piece
Steel TubingSteel Tubing1 piece
Hex Bolt - Grade 8.8Hex Bolt - Grade 8.81 piece

Tools needed:

MIG WelderMIG Welder
Adjustable WrenchAdjustable Wrench
3

Weld the head

Weld a head post (25) of square or rectangular steel tube square to a head beam (27) of rectangular tube. Weld a bracket leg (29) down from the beam's outer end, and fix support plates at both ends (31, 33).

Materials for this step:

Steel TubingSteel Tubing1 piece
Mild Steel PlateMild Steel Plate1 piece

Tools needed:

MIG WelderMIG Welder
4

Fit the trunnions and align the pivot

Fix a shaft through the head post with its ends out as trunnions (55a, 55b), in bushings in two bearing blocks (59a, 59b) bolted inside the channel webs. Each block has one close-fit bolt hole and three oversize ones: shift the blocks until the pivot is parallel to the bed plate, then torque the bolts. A set screw (67) takes out end play.

Materials for this step:

Steel ShaftSteel Shaft1 piece
Metal BushingMetal Bushing2 pieces
Bearing BlockBearing Block2 pieces
Hex Bolt - Grade 8.8Hex Bolt - Grade 8.88 pieces
Cup Point Set ScrewCup Point Set Screw1 piece

Tools needed:

Drill PressDrill Press
Torque WrenchTorque Wrench
5

Mount motor, belt drive and gearbox

Mount the electric motor (37) on a plate (38) pivoted on the head beam, and couple it by a multi-speed belt and pulleys (41) to a gearbox (39). Fit the drive wheel (43) on the gearbox output shaft.

Materials for this step:

Electric MotorElectric Motor1 piece
Mild Steel PlateMild Steel Plate1 piece
Drive BeltDrive Belt1 piece
PulleyPulley1 piece
GearboxGearbox1 piece
Band Saw WheelBand Saw Wheel1 piece

Tools needed:

Adjustable WrenchAdjustable Wrench
6

Build the idler tensioner

Weld an idler yoke (87) of rolled steel plate, pivot it on the head beam with a pin (89), and cantilever the idler axle from it with the idler wheel (45) on bearings (85). A threaded rod (91) pulls the yoke through a coil spring (93) held between compression plates and a U-bolt (97); a knob (99) turns the rod. An indicator (101) on the spring reads the tension on a scale (103).

Materials for this step:

Mild Steel PlateMild Steel Plate1 piece
Steel PinSteel Pin1 piece
Steel ShaftSteel Shaft1 piece
Band Saw WheelBand Saw Wheel1 piece
Ball BearingBall Bearing1 piece
Threaded RodThreaded Rod1 piece
Coil SpringCoil Spring1 piece
U-BoltU-Bolt1 piece
Control KnobControl Knob1 piece

Tools needed:

MIG WelderMIG Welder
Adjustable WrenchAdjustable Wrench
7

Build the two blade guides

In each guide channel (111) mount two guide rollers (115a, 115b) on ball bearings on eccentric bushings, one fixed and one adjusted to the blade thickness. Add a carbide thrust insert (133) on the blade's back edge and two carbide side inserts (137a fixed, 137b on a sprung swing bracket set by a bolt and knob). Clamp the guides on two bar tracks (107).

Materials for this step:

Guide RollerGuide Roller4 pieces
Ball BearingBall Bearing4 pieces
Eccentric BushingEccentric Bushing4 pieces
Carbide InsertCarbide Insert6 pieces
Coil SpringCoil Spring2 pieces
Control KnobControl Knob2 pieces
Steel TubingSteel Tubing1 piece

Tools needed:

Adjustable WrenchAdjustable Wrench
8

Fit the blade and set the tension

By hand, run the endless blade (47) round the drive and idler wheels and through both guides; the rollers twist its lower run about 90° so the teeth face down. Turn the tension knob until the scale shows the tension you want.

Materials for this step:

Band Saw BladeBand Saw Blade1 piece
9

Fit the feed cylinder and counterbalance

Connect a hydraulic cylinder (71) between bed channel and head post above the trunnions, filled with oil and piped through tubing (75) to a control valve (73): the valve sets the feed rate and, closed, holds the head. Fit a coil spring (78) on a threaded linkage (79) between an end gusset and the head post below the trunnions, adjusted by a knob (80), to counterbalance the head.

Materials for this step:

Hydraulic CylinderHydraulic Cylinder1 piece
Hydraulic OilHydraulic Oil1 batch
Hydraulic TubingHydraulic Tubing1 piece
Flow Control ValveFlow Control Valve1 piece
Coil SpringCoil Spring1 piece
Threaded RodThreaded Rod1 piece
Control KnobControl Knob1 piece

Tools needed:

Adjustable WrenchAdjustable Wrench
10

Bolt on the vice

Bolt the quick-acting vice to the bed plate to clamp the work square under the blade.

Materials for this step:

Machine ViceMachine Vice1 piece
Hex Bolt - Grade 8.8Hex Bolt - Grade 8.81 piece

Tools needed:

Adjustable WrenchAdjustable Wrench

Materials

29

Tools Required

4

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