Giant Bandsaw Restoration Project Part 1 of 4

hey guys welcome back to the shop as you can see behind me I have a 100 year old bandsaw and hopefully you guys can join me in getting it running so what are we working with this is a 36 inch bandsaw standing at over 8 feet tall and I place it over a hundred years old why do I need a bandsaw well this bandsaw is going to be better suited here for the shop that way I'm not mixing wood and metal together creating a potential fire hazard when I used to do all my plans for the bandsaw are to get this thing operational and I want to maintain the look and feel of this old style while still bringing it up to the 21st century the first thing I want to tackle to get the bandsaw running is this driveline this originally had a big belt drive pulley on here but it's non-existent anymore so what I do have is this 14 inch 3 ribbed cast-iron pulley I'm gonna mount it to the shaft by the way of this split coupler but what I did notice is the shaft is too long so we're gonna cut it off and then mill in a groove for a key way to be able to mount the split couple on to and with this pulley and the motor that I have planned for this we should be turning it around 4000 surface feet per minute which is pretty good for general purpose man song so I think it's gonna work out great let's tackle a shaft right now you're probably saying to yourself Jason why don't you just take the wheel off the shaft well I would but I'm a little afraid to break the hub so if the hub breaks as I try to pull it off well on this wheel is basically almost destroyed then so I'm gonna leave it on the shaft it's not broke I'm not gonna fix it I'm gonna be milling a standard key shaft at 3/8 inch wide around 220,000 steep if you don't have a milling machine but need a key way in the shaft you can purchase the shaft already with a keyway machined in it anywhere online there's one more thing I want to address when we put the pulley and everything on I want to make a thrust washer that will go in between the bearing housing and the pulley and also the wheel on the other side this will give the thrust some cushion and a wear surface so let's tackle that next so the best choice of plastic is going to be this Delrin AF and it's basically a fiber filled plastic that's great for bearings gears and surfaces it's going to see a lot of friction to save some material I'm going to split it and make a little bit thinner which will be perfect for the bearing [Music] brush-off the milling machine I wanted to glue these two parts back together again but I was unsuccessful little did I know Delrin and superglue don't mix well together [Music] now the time has come to install the Delrin washer the key the taper lock bushing and the pulley this is when the fun part comes where forget to install at all [Music] those guys we did it we got the pulley mounted we have a thrust washer in here we have shortened the shaft and look it spins now I have a target to tackle the next project and that's going to be as getting a motor mount fitted to this machine I'm gonna try to keep the motor fit as tightly as possible to this frame and I also have to think about how I'm gonna build a guard system this is the Beast that's gonna be able to take my finger off in a moment's notice if I'm not careful and it's a 10 horsepower three-phase motor spins at 1730 rpms and here's my plan of attack with it we have to build a motor mount now the motor mount the way I want to sit is see this little pocket right here in the frame I want to nest this motor somewhere in here that way it keeps this footprint small and out of the way of tripping hazard and it also really decreases the size of the guard that I need to make and come up with something beautiful that also matches the machine so that's gonna be our task before I make any expensive cuts on the water jet I find it's a good idea to use cheap material like wood or cardboard to do some preliminary prototyping first and that really helped me out in this instance where I messed up the radius on my first preliminary design and I was able to go back and adjust it on the second cut [Music] [Music] thinking I'm ready to do some machining now that we're all done here at the waterjet I got one two three four five six seven parts I got to tap some holes drill some through holes through these brackets into the ends of these gun looking tight parts and yeah should go pretty easy on the milling machine so let's go do that now this was supposed to be an easy hole but I quickly found out the bracket was hitting the head of the milling machine this hole has been a real pain so I ended up searching machines to make this easier [Music] I screwed up and I noticed that these holes were not drilled perfectly horizontal in the bandsaw which now caused my parts to be a skew when I went to assemble them so the simplest way to fix this is to make an oblong hole now it's really difficult with a normal drill bit but the solution is to use this tool right here which is called an annular cutter and it's designed to cut overlapping holes so I'm gonna just come down a good half a hole pop another hole in there and we should be good to go again and we could easily do this with an end mill too but this is the correct tool for the job cool one oblong hole didn't know I was gonna be making oblong holes today but there it is [Music] before I can do the final assembly I need to get this motor sled put together so why tapping some holes with my cool power tapper and then using the minion squares to line everything up perfectly I made myself a place to put a nice Filat weld that way I didn't have to do any be grooving when I went to go weld these parts together [Music] now that the sled is welded up square and perfect with the minion squares I'm able to use it as a fixture to permanently combine the whole system together so here's a little update on where we're at we've got all the parts cut and finally fitted to this cast which my fault I didn't measure these holes it's casting it's all not perfect but we got it working pretty good we have some in and out with this sled they can slide on these rails by this sled being able to slide back and forth it's going to be able to help me tension the belt and then this plate by design is matched to the motor and all you have to do is just bolt with these two bolts down to the slots on top of the sled and now you have a in and out the beauty of this is for any reason if this motor were to go bad I need to change it for some reason that all I have to do is just make a new one of these pieces of base plate that matches the motor base and then plop any new motor on top of here and off it goes so the next step we got to do is tap the holes to be able to go into these slots in the sled and then mount the motor up pretty simple time's come to put some belts on the motor and the pulley here this is a three ribbed belt system I don't really need three rib belts - we'll probably sufficient but we're gonna put three on here cuz well it'll look funny if we're missing one so now I need to order a belt and get it coming but now I need to know what length I need to get because this is a custom application there's a couple of ways we can measure the length of the belt for one we can do some math there's a formula this isn't the channel to get into math the second way is to actually go online and there's actually a pulley belt calculator where you input the diameter of your small pulley input the diameter of the large pulley and then give it the center to Center distance and it will spit out a number for you or maybe you're in the middle of nowhere and you just need a simple approach on getting a belt made here's one way you can do it you can just take a simple extension cord something that will sit close to the top rib of your pulleys you can wrap it around something like this make a mark with your pencil and then stretch it out and measure it with your tape measure and it'll probably be within a half an inch or so so that's a great way to measure the distance you need for a belt especially if you don't have a lot of adjustment and you need to nail that exact number so there's a cool little trick for you I think the next project we gotta tackle is building a guard for the pulleys in the belt I've built lots of guards over the years being in maintenance so this is something I always dread doing but I think it's necessary for this project but I'm gonna change it up a little bit and make it a little more challenging on myself and I have a couple ideas that I'd like to try and let me show you how I'm gonna do this the first thing I'm gonna do is make a plate with the water jet that's gonna mimic the profile of these two pulleys and then we'll surround it and wrap it with a curved piece of sheet metal to protect the belts if they were to come off now when those two pieces of metal join I want to try a different joint system something that's gonna look much like a zipper let me show you so I'm going for some kind of artistic look for this guard I don't want it to be real Plain Jane with some expanded metal and some angle iron I'm gonna try to be creative and push my skills past what I'm comfortable with so I'm gonna like to try this tab in slot connection this mechanical connection one being a slot one having this zipper like tooth tab and when these two pieces intersect with each other we can peen and bend over the tabs go into giving this zipper effect as these two parts are fastened together I think I'll kind of look neat but I made some sample pieces to test so let's go see how they perform at the vise the tooth shape is so that when we get to the part that the curved metal that we need to form around it we can get it started into the hole these two plates are bonded really well together you can see so I think I'm gonna go with this construction I think it'll look cool this edge that sticks out is kind of like a piece of piping on a piece of furniture this will cover the belts this will be that part that covers the front of the pulleys so I think this is a successful test I think I'm gonna run with it [Music] now that the guard is done I'm able to use the fireball magnetic shims to hold and position my guard in place while I design measure and build the brackets to hold the guard to the machine [Music] [Applause] [Music] it's always frustrating dealing with an ill-fated guard to gain quick access to the belts if ever need be I designed a quick slip fit bracket to help installation go fast and smooth [Music] well I'm really happy the way this projects turning out so far the guards been basically looking like how I wanted to and it's kind of matching the overall theme of the whole band saw I'm also interested to hear from you guys how should I finish the guard should we paint it rust it patina it leave it but I wanted to match the existing look of the band saw currently so please leave those comments down below and I will catch you guys on the next episode as we continue to work on the bandsaw

Channel: Fireball Tool

Views: 351,732

Keywords: fireball, Fireball tool, bandsaw, bandsaw build, fix bandsaw, restoration, refurbish, custom bandsaw, antique bandsaw, Yerkes bandsaw, saw, patina, antique, update bandsaw, motor mount, bandsaw part 1, huge bandsaw, doall, do all, doall bandsaw, mig welder, water cutter, welder, restore bandsaw, wood bandsaw, wood, lumber, mach 500, milling machine, woodworking machine, big bandsaw, old saw, woodcutting, band saw project, band saw, vintage bandsaw

Id: 0JwqvRHVOAQ

Length: 14min 27sec (867 seconds)

Published: Sat Apr 11 2020