Use a Portable Bandsaw

Few tools can make a job of cutting metallic tubing or other stock easier than a bandsaw. On those occasions when the stock cannot be brought to the machine, portable bandsaws offer the option of taking the machine to the work. Here are some basic steps for using this versatile and portable power tool.

Steps

 * 1)  [[Image:Bandsaw16_449.jpg|thumb|Large capacity bandsaw at the jobsite.]]Rent or buy the portable bandsaw best suited for your needs.  Commercial or Industrial Grade tools are expensive and often somewhat heavier than handyman or homeowner's grades, and most portable bandsaws fall in the former category.  Here are some options you may find on portable bandsaws:
 * 2) * Capacity. Since the stock or material you are cutting must fit in the throat of the machine, choosing one with sufficient capacity is essential.  Large capacity portable bandsaws can cut pipe or angle stock up to about 6 inches, whereas standard machines are limited to about 4 inches of diameter or width.
 * 3) * Power source. If you are working in the field where electrical cords are not practical, you may choose to purchase a battery powered saw.  These, however, are more expensive than the typical A.C. voltage saws, and have limited cutting times between battery recharging.
 * 4) * Brand choice. Most name-brands offer similar features and torque, and use a common blade length.  Common brands include Porter Cable, Milwaukee, Ridgid, and DeWalt, and are available at builder's supply centers and tool retailers.  Discount retailers offer off-brand tools which serve the same purpose, but may be of lower quality than the previous brands, at much lower prices.  Be aware that with power tools, as with many consumer products, you will probably get what you pay for.
 * 5)  [[Image:Bandsaw_638.jpg|thumb|Speed selector dial on this bandsaw.]]Familiarize yourself with the tool.  Portable bandsaws use a trigger switch similar to drills and circular saws, but usually are equipped with a separate speed selector so the sawblade moves at a speed suitable for the material you are cutting.
 * 6) [[Image:Bandsaw9_742.jpg|thumb|Holding the bandsaw while cutting a vertical rebar, the trigger is behind the operator's right hand, and is depressed with his thumb.]]Use the two handles, one located on each end of the saw to hold the tool while it is operated.  This will allow you to guide the tool, while maintaining complete control of it.  Other notable components your should be familiar with are these:
 * 7) *[[Image:Bandsaw6_405.jpg|thumb|The tracking adjustment screw on this model saw.]] Tracking adjustment. This feature allows you to adjust the path the bandsaw's blade travels as it revolves around the rear drive pully and the foreward idler pulley.  Because the front pulley floats on a spring tension hub assembly, it must be adjusted so the alignment cause the blade to travel positioned correctly on these two pulleys.
 * 8) *[[Image:Bandsaw2_707.jpg|thumb|The tension control lever, which is turned to release tension when installing a new blade.]] Tension release handle. This handle, located on the forward end of the saw, is released to allow the operator to quickly and easily change the bandsaw blade if it becomes dull or is not suitable for the task at hand.
 * 9) * Guide rollers. These roller bearing assemblies support the blade as it is engaged in cutting your material so it doesn't deflect or bind.  Because the bandsaw blade is made of a thin, flexible metal, these rollers must rotate freely and be positioned correctly to prevent the blade from binding or warping during the cut.
 * 10) * Cutting shoe.  This is a flat, notched metal guide which will support the saw to offset the drag of the blades teeth as they cut the stock.  This helps to insure the metal being sawn will not be dragged into the rear drive pulley while you are cutting.
 * 11)  [[Image:Bandsaw1_477.jpg|thumb|This warning label is not a substitute for reading the operator's manual.]]Read the operator's manual and become familiar with unique characteristics of your choice of saws, and especially the safety recommendations from the manufacturer.  Bandsaws operate with an exposed blade capable of cutting through almost any common metal from soft copper to cast iron and steel, and will cut fingers with no discretion.  This is one reason why the operator should keep both hands on the provided handles (located on the back of the saw, away from the blade).
 * 12)  [[Image:Bandsaw8_266.jpg|thumb|Notice no loose clothing or jewelry is near the saw blade in this photo.]]Dress appropriately for using this tool.  Safety glasses and gloves are very important, but also keep in mind that loose jewelry or clothing can easily get caught in the moving blade.
 * 13)  Support loose material when cutting.  Using a vice or having a helper to hold a round pipe or bar will prevent it from spinning in response to the blade biting into it during a cut.  Metal which bends during the cut can bind the blade causing the operator to lose control of his saw, and heavy items can drop on the operator's feet when they fall free.
 * 14)  Mark the stock you are cutting at the correct angle for your needs.  Mark pipe around the diameter so the finished cut will be true.
 * 15)  [[Image:Bandsaw12_770.jpg|thumb|Here the cut is started into the rebar.]]Place the sawblade against the stock to be cut, making sure the blade is parallel to the cut line you have marked, and perpendicular to the stock (if the cut is to be square, or 90 degrees).  Keep the shoe of the saw firmly against the stock.
 * 16)  Start the saw by squeezing the trigger and allow the saw to cut its way through the stock you are cutting.  Do not force the saw or apply excessive pressure, as the saw's teeth are able to remove only a certain amount of material with each pass.  Rocking the saw when cutting very thick, solid pieces of stock may allow the metal chips to clear the saw's kerf, but usually, holding the saw steady in relation to the cut is the best method.
 * 17)  Watch the blade to make sure it is aligned with your cut mark, and slow the cut when you are nearly through the stock so you can anticipate the blade binding if the material flexes or bends suddenly.  Check the free end of the stock to make sure there is nothing in the way of it when it drops off.
 * 18)  Release the trigger and allow the blade to quit moving before setting the saw down after the cut is complete.  Set the saw on a clean, level surface when the cut is finished, to insure it does not fall and become damaged, or get dirt or debris in the pulley assemblies.

Tips

 * Choose a blade appropriate for your task. When cutting metal, especially thin metal or tubing, you should make sure at least 2, and preferably more, teeth engage the metal at all times.  Selecting a bandsaw blade with the correct TPI (teeth per inch) for your intended use will give you the best results.
 * Keep your tool clean and in good condition. Dirt or debris can cause your saw to bind, destroy the roller guides, and shorten the life of your tool.
 * Supporting the stock you are cutting is essential for a good, clean, safe cut. A pipe vise is recommended for cutting any type of tubing.

Warnings

 * Portable bandsaws operate with an open, or unguarded blade capable of cutting almost anything that engages it when it is moving.
 * Always unplug the saw when changing or replacing the blade.
 * Heavy steel or other materials can cause damage to floors, and serious injury when they fall loose after the cut is completed.
 * If you force the blade into the material, you stand a chance of breaking the blade. When this happens, the blade becomes a projectile and will kill or maim whoever is in the way.

Things You'll Need

 * Portable bandsaw with suitable blades.
 * Power cord/power source.
 * Safety equipment.

Related Tips and Steps

 * How to Arc Weld
 * How to Use a Cutting Torch
 * How to Use a Steel Chop Saw
 * How to Use a Circular Saw