DIY Bandsaw Blade Welder

[ac...@provide.net]

Has anyone attempted to make one?
Having a way to fix broken blades, and resizing easily
available ones may be a useful thing.

I'm curious if anyone here has made one yet.

OOC... in addition to things like hacking a microwave
transformer and adding a machined jig, is there a way
to make a jig for a laser cutter/engraver, and writing
a program? (Or is that too low powered?)

Keith Mc.

[James Foulke]

Keith,

Have you researched journals like Home Shop Machinist?   

Two questions, first: what should a jig look like?  Would a block with a groove and gap be sufficient?

And second, is there an alternative to electric welding, perhaps braze or silver solder.

Grinding the blade ends would seem to be critical.   Perhaps a jig to set the grind angle( and bevel).

Good luck      Jim

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[M. Adam Davis]

My understanding is that if you're doing it on the cheap you can simply braze them with silver solder and a torch.  No need for real welding or anything fancy, particularly if you aren't doing production work and replacing the blades every week anyway:

http://www.practicalmachinist.com/vb/fabrication-cnc-laser-waterjet-plasma-welding-and-fab/pros-cons-practical-reality-using-bandsaw-blade-welder-249341/

If you have a welder, or can borrow a cheap one, or use a 20% off coupon for the $80 harbor freight stick welder, then you don't need to do anything fancy like resistance welding. Cut the blade to length, line up both ends along a straight edge, weld, then file or grind the weld flat.  You're done.

If you want to use bimetal blades (which have a longer lasting cutting edge) then you have to follow an annealing process which will require a torch.

But for what you're doing, I don't see why you need to go that far - get a torch, silver solder, file or grinder, and call it good:

http://www.carbideprocessors.com/pages/brazing-carbide/bandsaw-blade-brazing.html

If you really need a resistance blade welder, here's an older article showing a DIY version:

http://www.packratworkshop.com/pdf/BandsawBladeWelder2.pdf

Having never done it myself I can't give any further feedback, but let us know how it goes if you go down one of these paths.

-Adam

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