This is a project I’ve been wanting to do for a while now, ever since I saw the great videos by Matthias Wandel ( http://woodgears.ca/ ) of his shop-made bandsaw. A bandsaw is a tool that I don’t yet possess and my budget is far too small to afford “enough” bandsaw to make me satisfied. I enjoy veneer work and finishing, and working with figured wood is a lot of fun. Being able to resaw my own veneer slices is a capability I would really like to have, however the commercial bandsaws that fit within my budget have abysmal resaw capacity, in the 4-6” range for most cast iron 12” to 14” units.
So I set out on a journey… Well, I’ll let the pictures speak for themselves. Some of them are slightly out of chronological order. Building the frame took about two weeks of working for a few hours each night after I got home from my day job (as a software engineer).
Please make fun of me for my messy shop… I clearly need some serious motivation to do something about it.
I designed the entire thing in Solidworks. I’m not sure if I will try to sell the plans or not, they are quite comprehensive but are customized for the materials and parts that I was able to acquire inexpensively.
Surfaced, cut to length, and labeled
Beginning the glue-up
When I did the initial glue-up I was using Titebond II but I quickly switched to a urea-formaldehyde glue after the first two laminations were glued together. (DAP Weldwood Plastic Resin Glue).
Stabilizing a few knots with some extra glue
Frame is complete sans two pieces I forgot to attach earlier
The frame as it is now weighs about 80-90lbs, perhaps more. I’m not a body builder or anything so it takes a not insignificant amount of exertion to even rotate the frame from lying down to standing on it’s back. It might even be more than 90lbs, I’m using that figure based on what Solidworks told me that it should weigh but I had plugged in red oak to solidworks and got about 84lbs. This is somewhat tight grain doug fir, and some poplar and it may be denser than red oak. Or maybe I’m just a wimp.
-- Woodworking from an engineer's perspective