Some days you can't miss, then there's every other day...
My metal cutting technology in the garage is pretty standard. I've got a couple hacksaws, a sawzall and jig saw with metal cutting blades, grinders with cutoff wheels, and my Evolution Rage3 miter saw with a muti-material blade that serves as a dry cut saw on lighter gauge metals. Like the old pick two racer's 'fast, cheap, reliable' dilemma, I have a similar situation in the garage when it came to metal cutting. Between all of my tools, I'm always working with some sort of compromise between precision, speed, and material thickness.
A hacksaw is precise and can handle thick material, but it is very slow. A sawzall is fast and can handle thick material, but its not precise. The jig saw and Rage3 are precise and fast, but can't handle thick material. An angle grinder with a cutoff wheel is probably about as dead center between those three as it gets. It is reasonably fast, precise enough for most jobs, and can handle most material thicknesses within reason. The downside being that it is messy as hell and requires a fair amount of PPE to operate safely. The solution? A portable bandsaw of course.
I've been eying a portable bandsaw for awhile now and when HF had them on the tent sale a few weeks back for $85, I picked one up. I'm hoping the portaband can be a better version of the angle grinder - cutting thick materials relatively quickly and precisely, but without all the dust/mess. I also have an upcoming project that it will be very useful for, so I figured it was just as good a time as any to get one.
Not that I needed any justification because as we all know, being clearly stated in section 4.3.2a of the GJ bylaws, wanting a tool is the only justification that is technically needed to purchase it. The fact that I came up with an additional need for the tool (subsection 2b), as well as the tool being on sale for a marginal discount (2c) means I was clearly in the right for purchasing it. I'm even in compliance with the Spousal Notification section (4.3.3b) that states that leaving said tool out in the open for your wife to see is considered adequate notification of its purchase, regardless as to whether she notices or comments on it.
The part of this project that gave me aggravation is that I wanted to have the saw mounted on a table. I really like the SWAG portaband tables (
https://www.swagoffroad.com/SWAG-Portaband-Tables-Accessories_c_35.html) and figured I'd take a shot at making my own. So I found a 12"x12" piece of 1/4" plate and got to work.
View media item 102314
Everything was humming along well. I used a piece of cardboard to find the cutout shape for the rear of the plate and to locate the holes. I welded a small plate on the bottom to allow the screws to countersink into the top. Brimming with confidence, I measured and cut a slot in for the blade.
View media item 102315
Thinking I was smarter than the average bear, I cut the slot in from the front of the table instead of the rear so that I would be able to change the blades without removing the saw from the stand. This, as I realized nearly immediately
AFTER making the cut, was a dumb idea. If I wanted to change the blade without removing the saw, I also would have to put the table on its side or tip it so the blade would clear the legs. I want to enclose the base for a more finished look - having a front loaded blade would make this more complicated. Finally, if I ever needed to remove the saw from the table, I'd have to take the blade off to get the saw out. All of these issues I was willing to work around (I like a challenge and I'm stubborn) but when I tried to fit the blade, I found that I'd measured incorrectly and my slot was about 1/4" off from where it needed to be. Sh*t. No pics of the misalignment, I was too frustrated in the moment and called it a day. I'm still not sure how I screwed this up, but a mistake was made and needed to be fixed, no sense in obsessing over the past.
After thinking about it over a few beers, I decided the best course of action would be to weld up the front slot (didn't have any more plate laying around) and cut a new one from the back (like everyone else does). The next day I got to work.
View media item 102316
My apologies for not taking step-by-step photos, I was too focused on trying to get the plate fixed. Here's a little description of what I did... I started by grinding the slot wider and deeper to allow the weld to penetrate into the base material. I also started on the bottom of the plate so that I could work out my process on the side that no one will see. Keeping the plate clamped flat during and after welding is key to reducing the warp. When welding, skip around to distribute the heat evenly. Once welded, grind/sand/blend the welded area flush, taking care to not dig too deeply into the base material with the grinder. The goal is to only remove the weld, which is easier said than done. Once you have one side welded and blended, and you've allowed the part to cool while being clamped flat, flip the plate over and repeat. Working from the top side, I ground the slot deep enough to start seeing the weld I'd just applied from the other side. Doing this ensures full penetration and voids in the material will be kept to a minimum. If all goes well, its as if you never made a mistake in the first place.
View media item 102317
I then measured out the slot location. And measured again. And again. And rechecked once more. Then I cut a new slot.
View media item 102318
Success! Perfect fit. Even better, when I checked the perpendicularity of the blade to the surface of the table, I was only off by 0.1 degrees, which is pretty good all things considered.
View media item 102319
Then I started to remove the plate to weld legs to it, and stripped the head of the screw. Pretty much par for the course on this project. But, as luck would have it, I happened to have a handful of the exact same size screw in inventory. No idea where they came from because I don't do a lot with metric at home. Either way, I was glad I spent all that time a few years ago organizing my hardware because it turned what could have been a half hour round trip to the hardware store into a two minute minor inconvenience.
The next step was putting on some angle iron legs. I used the saw to cut them and couldn't be happier with how easy and quick it is to use.
View media item 102320
And that was as far as I got on the portaband table this weekend. I'm going to enclose the base, mount a plug/switch to turn it on/off, and do some sort of tray to catch the shavings. As some of you might now from older posts, I like to name some of my tools. The names can't be forced, they have to come naturally. I've got a special name picked out for this rig that will be revealed when I post pics of the final product.
The baby is due any day now (today is actually the due date) so we'll see how soon I get around finishing the portaband table. The motorcycle is also still in the works, I need to go get a new rear tire and to make some other decisions about where I want to go with things. Again, pending baby, not sure how soon I'll be posting again.