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Portable Cordless Bandsaw Jig.

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Project by LittleBlackDuck posted 11-26-2017 11:39 AM 917 views 2 times favorited 16 comments Add to Favorites Watch

I apologise to any strangers to my style of posting and doubly to those that are familiar.

Unfortunately any good duck tale has to have the scene set, to supplement the taradiddles that will support my enthusiastic imagination.

My latest shady accountant had a powwow with WHMBO and they both conceded to permit me to purchase a therapeutic spa tub. Why therapeutic… well you hold your nose, put your head underwater and contemplate what would happen if the missus locked the lid so you couldn’t surface… beats yoga.

Now here in Victoria (Aust.) it is mandatory to have a child proof fence around anything aquatic larger than a lidless tumbler of water.

Well in downtown Churchill, not being inundated with fencing contractors, I could not get anyone to undertake the project and anyone that bothered to quote, would require me take up a full time job for the next 5 years for any potential settlement.

So this little black duck decided to undertake the project by himself and with the money saved, could justify the purchase of a portable cordless bandsaw for cutting the aluminium fence to size… hey my hacksaw does NOT have an ON/OFF switch.

OK, this now leads me back to my mainstream story. I now have a cordless bandsaw that I would like to take the work to rather than it to the work. Inspired by Bluenote38 Portable Bandsaw Stand , I decided to make a stand for it. Being portable with a big fat battery on its back I had to deviate from B38’s design and try to come up with something to fit my malformed twisted blade.

I took a few measurements, a couple of angles and quite a few mouthfuls of vino and did a mock SketchUp drawing of a cradle. Waited for the alcohol to evaporate out of my brain, I then hit the workshop. After recovering from the resultant bruises and armed with the SU measurements,

I started to hack some shapes out of a lump of 18mm MDF.

Cut out a recess to hold the handle I was surprised at how my measurements were accurate enough that the bottom actually sat on the bench. I cut out a few triangles in accordance with the angles I measured and butted them against the bandsaw “bottom” to brace it. Hmm, it actually fit and was more stable than I imagined. As I had to allow for the battery, there was too much clearance around the body so I glued a shim against the inside left frame to take up the slack. I had some plastic wedges,

(please don’t ask me where I got them from… don’t ask… don’t… please… ah… ah-ha… NO!) that I jammed in on the other side and that secured the body and stopped any potential movement. I then attached another “triangle” on the other side of the bottom.

It was not according to plan but more so an “as fit” fit. Not pretty but functional.

Now I was faced with the issue of switching the bloody thing on. I initially planned some cut outs to access the trigger, however, as the trigger didn’t have a locking switch, I somehow came up with the design of a through rod that I could use as a lever. I drilled a holding hole on the left hand side and an elongated hole on the other to permit lever downward travel. I drilled on of the holes in the wrong position, however, I hid it behind a cover block so only the most observant person would notice it (if they opened their eyes). I attached a spring to the end and when it didn’t work, I flipped the lever horizontally so the spring was now at the elongated hole end.


Miraculously the tension on the spring wasn’t enough to pull the lever down, however, once manually pulled down it had sufficient tension to hold it in the “ON” position. Lifting the lever turned the saw OFF and when the lever was released it stayed OFF. What a great design and sheer arsed luck!

Added a couple of clamps to the base to hold the jig stable against my bench.

One of my primary intentions of using this saw was to shorten the egos of some of my smart arsed long bolts. I always found that to use a hacksaw or a Dremel metal cutting wheel was just too cumbersome so the first thing to do was design a stable “tabletop” for the saw. I then found that for ease of use a cradle/sled would be a handy attachment. It worked like a charm for small bolts/screws,

Small aluminium tubing,

and even brass pen tubes though the blade I used left a rough cut….

maybe a “greater” TPI would serve better, however, having a small tube cutter this was just an exercise in versatility.

The sled may be a bit small for large bolts but then I can easily hold them in a vice and hack it to pieces using the saw hand held.

The cradle/sled components (except for the “V” support which was done on the router table) were cut out on the laser, super glued with the moving parts used to ensure free movement as the glue set. Added some wax to smoothen the movement and make it all smell pretty.

I created another tabletop and modified it to take a small mitre gauge (that came with my small belt sander), for all those flat pieces of metal,

and for those cantankerous pijani hinges,

All in all I was happy with the build and again I sincerely thank Bluenote38 for the inspiration. Mine is not a pretty jig and I haven’t attempted to pretty it up as the first attempt was just a proof on concept but as it worked first time I thought I’d leave it as is. I did give it a coat of tung oil to give it a bit of a tan.

If I have to remake it, I will make it out of solid wood (pine) if only to stop the splitting of the MDF due to the screws. The SU will need to be altered to change the 18mm thickness to 19mm, however, that would be a very simple operation in SketchUp without the need for an anaesthetist.

Again, for all those that hate reading… rather than read the above, have a look at this video I posted on YouTube

PS. If you want to ensure your manhood is preserved and the saw doesn’t jump out of the jig and attack you, you can add an optional retaining strap…

-- If your first cut is too short... Take the second cut from the longer end... LBD





16 comments so far

View Bluenote38's profile

Bluenote38

219 posts in 224 days


#1 posted 11-26-2017 01:17 PM

Very nice! I really like (translate: I’m copying) your “switch”. Mine’s just a little piece of scrap wedged into the trigger. I also like the tables. Mine’s just a flat steel plate so a couple more ideas of yours I need to implement. So many possibilities.

Well done my friend.

-- Bill - Rochester MI

View GR8HUNTER's profile (online now)

GR8HUNTER

2956 posts in 548 days


#2 posted 11-26-2017 01:55 PM

is that graffiti on your shop walls in picture 2 :<))

-- Tony Reinholds,Pa. REMEMBER TO ALWAYS HAVE FUN

View bushmaster's profile

bushmaster

2502 posts in 2119 days


#3 posted 11-26-2017 03:23 PM

Very interesting, being in the far north woods I have never heard of a battery powered bandsaw, why not, everything else is battery powered. I am sitting here using a battery powered computer with a battery powered internet connection hub, in pitch black darkness. Power is off this morning, snow, trees on the line I guess. Hurray for battery power.
The stand is great and your cutting jigs work well. Nice build.

-- Brian - Hazelton, British Columbia

View woodbutcherbynight's profile

woodbutcherbynight

3644 posts in 2245 days


#4 posted 11-26-2017 03:57 PM

Interesting project. Really like the explanations about details with all the pictures.

-- Live to tell the stories, they sound better that way.

View woodchuckerNJ's profile

woodchuckerNJ

1244 posts in 1470 days


#5 posted 11-26-2017 04:29 PM

I made a table about a year ago.
https://imgur.com/a/WE6dW I modified mine to have an adjustable trigger speed. But usually just keep it on high.
But I didn’t enclose it. Your’s looks like you are blocking some of the cooling vents. Mine is electric and doesn’t have as many as yours. You may want to expose some more of the cooling vents.

-- Jeff NJ

View Bruizer's profile

Bruizer

6 posts in 375 days


#6 posted 11-26-2017 05:45 PM

WHMBO?

View pottz's profile

pottz

2220 posts in 820 days


#7 posted 11-26-2017 08:34 PM

not bad ducky great way to repurpose,i could have used that yesterday!story is a little long in the tooth as usual but I expect no less.nice work buddy.
ps-cant wait to see rc’s take on this one!

-- sawdust the bigger the pile the bigger my smile-larry,so cal.

View LittleBlackDuck's profile

LittleBlackDuck

1310 posts in 657 days


#8 posted 11-26-2017 09:13 PM

Thx B38, before your post I didn’t even know these existed and in the few days I’ve owned it I’ve managed to use more times than winning tatslotto.


is that graffiti on your shop walls in picture 2 :<))

- GR8HUNTER


Gr8 eye GR8! Sprung! Woke up with a throbbing hangover the other day and felt rebellious. Decided to do some tagging… Unfortunately it was 38°C outside so rather than venture into the furnace I went troppo in the workshop with some black grease.


... never heard of a battery powered bandsaw… battery powered computer… battery powered internet connection hub…

- bushmaster


That’s progress for you bushie. We cannot curtail progress… soon we’ll be using battery powered batteries!

... looks like you are blocking some of the cooling vents…

- woodchuckerNJ


You are right chuckie... I never considered that in the equation… however, I did fail maths as school.

Fortunately my intention is for quick dirty small work… insufficient load and run time to be of too much concern.
After a cut, counting my fingers will give it some opportunity to cool down.


WHMBO?

- Bruizer


See my comment about that throbbing hangover above. Wasn’t thinking straight and that bloody built in spell checker must have had one also. SWMBO will be giving me a better serve than Venus Williams and giving me a few of your namesakes (bruiser(s)!


... i could have used that yesterday… is a little long in the tooth…

- pottz


If you like, I can look into backdating the article to yesterday… or even the day before in case you miss it!

As for length.. I have to compensate! Furthermore, everyone knows ducks don’t have teeth… at least not canines!

-- If your first cut is too short... Take the second cut from the longer end... LBD

View robscastle's profile

robscastle

4510 posts in 2040 days


#9 posted 11-26-2017 11:40 PM

Wife who must be obeyed ..how hard is it? ... opps I mean oh anyway
You Victorians have got it made, Multi faceted weather, therapeutic spa tubs Battery operated bandsaws, all the tools in the country located in one place, and even a teleporter! how good is that!!

I looked at these devices some time ago with a view to making a minature bandsaw mill as I didnt think the wife would appreciate a lucas mill stuck under the clothes line.

I was unable to find a real Horizontal bandsaw regardless of it was for wood or metal.
This came about after I tried to mill a pine log on my poor bandsaw, see blog.

It appears that no horizontal bandsaw with and resemblence of portability has been built with the blade 90 degrees to the frame, allowing you to mill with it.

Yor post and accompanying video is most impressive however once the fence is built what are you going to do with it?
Why didnt you just buy a Air powered hand hack saw? brilliant for lopping the heads of recalcent bolts, or just go for the nuts!

I think you should call it the Hazelwood Revenge for attacking slack tradies later

You are a busy boy, and no no no I dont want to see any pictures of you in the Spa!.

-- Regards Robert

View pottz's profile

pottz

2220 posts in 820 days


#10 posted 11-27-2017 12:08 AM

You are a busy boy, and no no no I dont want to see any pictures of you in the Spa!.
—Regards Robert.

I second that rob, a duck in a tub,gives me shivers buddy-ha!

-- sawdust the bigger the pile the bigger my smile-larry,so cal.

View LittleBlackDuck's profile

LittleBlackDuck

1310 posts in 657 days


#11 posted 11-27-2017 06:26 AM


... You Victorians have got it made, Multi faceted weather, therapeutic spa tubs Battery operated bandsaws, all the tools in the country located in one place, and even a teleporter! how good is that!!


Churchill, Victoria… The land of the blessed!


Why didnt you just buy a Air powered hand hack saw?
- robscastle

Never tried one of those… I have tried cordless reciprocating saws, air powered cut off wheels but found the best item for small bolts (no… not the recalcitrant ones that fight back) was my Dremel’s cut off wheel… however, I either get sprayed with a facefull of sparks or if angled away, keeps shorting out and have to continually reset it. I disagree with Malcom Fraser’s “Life wasn’t meant to be easy” and I’m too old to get hassled by obstacles and strive for the easy path… If there is an easier way to do something I pick it… Now if you believe that bull you have been totally sucked in… I just love gadgets and tools… my greatest fear of death is all those great gadgets that will be invented after I’m gone!


... a duck in a tub,gives me shivers buddy-ha!

- pottz


What’s your problem pottzy... ducks don’t wear pants anyway (look at Donald… no not the Trump) so why discriminate with the spa?

-- If your first cut is too short... Take the second cut from the longer end... LBD

View robscastle's profile

robscastle

4510 posts in 2040 days


#12 posted 11-27-2017 08:05 AM

OMG ha ha ha thats a come back that cannot be beaten!!

-- Regards Robert

View htl's profile (online now)

htl

3148 posts in 995 days


#13 posted 11-28-2017 03:20 PM


is that graffiti on your shop walls in picture 2 :<))

- GR8HUNTER


Looks like Ted to me ain’t he the guy who makes all them 5000 plans for free sites???

Great job on the saw, couldn’t that be used as a cheap small wood band saw as well?
Would work great for making Dutchys band sawed tyre treads ME Thinks

-- There's a hundred ways to do anything, alot depends on the tools at hand.

View LittleBlackDuck's profile

LittleBlackDuck

1310 posts in 657 days


#14 posted 11-29-2017 10:52 AM


Great job on the saw, couldn t that be used as a cheap small wood band saw as well?
Would work great for making Dutchys band sawed tyre treads ME Thinks

- htl


Good thinking #4. The blade is too wide (1/2”) for tight curves and the throat is only 120mm deep, however, that line of thought has potential and a helluva a lot safer than a full speed bandsaw.

-- If your first cut is too short... Take the second cut from the longer end... LBD

View crowie's profile

crowie

2036 posts in 1787 days


#15 posted 11-29-2017 10:04 PM

Absolutely brilliant Ducky use of the Milwaukee M18 Bandsaw
https://www.milwaukeetool.com/power-tools/cordless/2729-22
You need to pattern the jig and sent it off [sell it] to Milwaukee Tools…
You are certainly one clever innovator…

-- Lifes good, Enjoy each new day...... Cheers from "On Top DownUnder" Crowie

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