- How to Join a Band Saw Blade
- Step one: Prepare your tools and materials
- Step two: Cut the band saw blade
- Step three: Grind off material from both sides of the cut line so that they meet perfectly
- Step four: Clean up with an abrasive wheel or wire brush
- Step five: Attach your vise to a stable work surface
- Step six: Attach the band saw blade section to your vise
- Step seven: Attaching the band saw blade sections together without grinding
- Step eight: Repeat previous steps until your band saw blade is complete!
If you are looking to increase the durability of your band saw blade, or if you want to make a new one, this blog post is for you. Follow these easy steps and learn how to join a band saw blade in just seven simple steps!
How to Join a Band Saw Blade
We prepared 7 steps on how to join a band saw blade.
Step one: Prepare your tools and materials
To join a band saw blade, you need to prepare the following:
- A vise (or another way to hold the blade in place)
- An angle grinder or bench top belt sander (to grind off material from both sides of the cut line so that they meet perfectly)
Step two: Cut the band saw blade
This step is to cut the whole length of the band saw blade.
Make sure that you use a metal cutting abrasive wheel for your angle grinder or benchtop belt sander, which should be able to fit into any standard tool holder. You can also ask someone at an equipment rental shop if they have one available which would work best with your tools and materials.
It’s important not to touch either side of this newly-cut section because it will still be very hot after being cut through by whatever method you used (angle grinders are typically 1000 degrees Fahrenheit). This heat could cause serious injury so make sure hands are completely away from both sides while cooling down!
After cutting through, set this band saw blade section aside and let it cool completely.
Step three: Grind off material from both sides of the cut line so that they meet perfectly
Once you’ve gotten this far, use an angle grinder or benchtop belt sander to grind off any excess metal on either side of the newly cut length until it is flush with the rest of your band saw blade.
As usual, make sure not to touch edges because these are still very hot! This will take some time but eventually, you should get a clean edge where no extra metal remains sticking out beyond what’s already been locked into place by joining other sections together.
If grinding doesn’t work for whatever reason (either there isn’t enough space between these two lengths or the metal is too thick), you can also try using a benchtop belt sander to sand the excess away.
Step four: Clean up with an abrasive wheel or wire brush
To clean off any residual dust and/or particles, use an abrasive wheel on your angle grinder (which should be attached to either your tool holder or the drill) or a wire brush for cleaning if using something like our Bench Grinder Stand.
This will help ensure that no stray swarf gets left behind during joining so later it doesn’t interfere with how well everything fits together. It’s important not to touch the newly cut length yet because these are still very hot even after grinding! If necessary, let this band saw blade section sit in a safe place where children or pets can’t reach it while cooling down.
Step five: Attach your vise to a stable work surface
Make sure that the band saw blade is supported by its handle in order to avoid potentially rendering your new longer piece useless if too much weight causes it to warp out of shape! This will help prevent any problems when trying to join two pieces together later on.
You’ll want something sturdy like our Bench Vise Base for this, which has very wide teeth perfect for gripping metal securely without slipping even under high pressure. The jaws are also slightly wider than most other vises so they’re good at locking onto objects with irregular shapes, making them easy and quick to use no matter what you might be working on.
Step six: Attach the band saw blade section to your vise
Now that both sides of this new cut length have been cleaned off, it’s time to join them with previously cut sections in order to attach them together!
Use a flat file held against one side by hand or using an adjustable wrench as shown above.
Make sure not to press too hard because you could end up accidentally damaging the teeth on either side of your freshly ground edge if they’re pressed down too far while filing. Gradually work back and forth across each side until the metal is flush everywhere.
Once it’s looking nice and smooth, use a benchtop belt sander to remove any areas where the metal is raised while simultaneously smoothing over previously filed sections.
This will make everything look more even before you move on to joining! After that, use an angle grinder or file again to make sure there are no remaining burrs sticking out on either side of this new cut length.
If necessary, use your flat file at an angle for getting into tight spaces like underneath one another because these types of files come with teeth that can be easily oriented in whatever way works best for whatever job you might have to do next.
You don’t need anything fancy here since any type of standard triangular flat file should work fine without damaging steel surfaces.
Step seven: Attaching the band saw blade sections together without grinding
One of the most popular methods for joining two pieces together is by using cold rollers.
These are simple cylindrical metal objects which come in various different diameters (but should be at least slightly smaller than what you’re trying to fit onto). Simply slide these underneath where your new length meets one side, then use a hammer or mallet until they’ve evenly locked into place on both sides!
The more pressure applied while hitting them like this, the tighter everything will become once it’s all cooled down and ready to go. If necessary, wait until that section has had time to cool off completely before adding additional roller sections if any extra space still exists between where these join.
Step eight: Repeat previous steps until your band saw blade is complete!
After all the work you’ve done so far, it should be easy to see how much more durable this longer piece of steel has become compared to its original state before joining together! As long as everything’s been ground down evenly using a bench grinder and filed smooth afterward, there shouldn’t be any sharp edges anywhere along with it either which could potentially cause injury.
If you find yourself needing one section or another during use later on, simply heat up that part with an acetylene torch again in order for the metal to expand slightly enough for sliding out from underneath these cold rollers without damaging its appearance.
Once you’ve heated it back up to its original temperature, slide the pieces apart so that one side can be easily cut off using an angle grinder or benchtop belt sander before cutting all the way through whatever was left of your first band saw blade length with either a hacksaw or metal-cutting bandsaw depending on how thick it ended up being after joining.
If you need to take a break at any point for whatever reason, simply keep these pieces in their original position so that they don’t slide out of place anywhere while cooling off again afterward!
With these steps, we hope that you’re going to have a much easier time joining band saw blade lengths together in order to make them stronger and more durable compared to originally heating up the entire blade itself when it’s already been connected back into its original form.