Shop-built bandsaw sawmill #2: first welds and preparing the threaded rods - July 2016

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Blog entry by Sodabowski posted 06-30-2017 08:45 PM 2977 reads 0 times favorited 5 comments Add to Favorites Watch
« Part 1: the plan Part 2 of Shop-built bandsaw sawmill series Part 3: mobile frame all welded up! - July-August 2017 »

Well for the first welds sorry, I forgot to take pictures. Long story short, I started by welding the two sides of the cutting head, those that will receive the threaded nuts for the blade height adjustment.

After carefully stick-welding the nuts, some proper cleaning was in order, since the penetration is so high with stick-welding. By the way, I used 6061 rutile electrodes, which gave nice control and results, with little slag to remove.

After that, I re-threaded the nuts to ensure a fluid movement without any risk of binding. I first used the hand wrench to clean up the taps and then ran the second tap several times with the drill to really make sure the excess was gone:

Next was doing the same thing with the threaded rods, since stock hardware is by no means designed for such applications. So to remove all the burs and irregularities from my threaded rods, I ran them with power across the M10 die, with lots of WD40. The amount of metal that I removed was higher than I expected, but the results worth the trouble:

Then a good cleaning was in order, first with a paper towel to remove the bulk of the chips, and then with a wire brush to get rid of everything:

And here’s the result: the upper rod is freshly re-threaded, the second one is still in its rough form, quite a difference : the thread is narrower but most importantly the surface finish is way better:

Crappy die:

The fit between the threaded rod and nuts is great, with little play and no binding whatsoever. SO I can move on to the next step, probably one of the most important ones: welding up the cutting head, ensuring absolute squareness of every joint and parallelism of the two sides. Quick-slap jig over a particleboard, welding magnets, and that’s the cutting head assembly taking shape:

This is how I left it, I couldn’t get back to it on the following holidays because there was SOOO MUCH to be done in the garden and in the bedroom. Next step will be to build the sides of the carriage onto which this part will be attached by the threaded rods, probably with casters too if there is too much sideways shake.

Nothing to call home about for now, but you gotta take the first step, right?

-- Thomas - there are no problems, there are only solutions.

5 comments so far

View shipwright's profile


8452 posts in 3399 days

#1 posted 07-01-2017 05:46 AM

I’ll be watching. Looks pretty interesting. Enjoy your summer break Thomas.

-- Paul M ..............the early bird may get the worm but it’s the second mouse that gets the cheese!

View Porchfish's profile


860 posts in 3133 days

#2 posted 07-01-2017 02:17 PM

If god wanted us to have particle board furniture, he would have given us trees that smelled of formaldehyde and made us all sick !

I really like what you are doing. Keep posting your progress goodon’ya (couldn’t continue to pass on the fiberglass v particleboard thingie …ha ha ) Don S.

-- The pig caught under the fence is always the one doing all the squealing !

View Schwieb's profile


1896 posts in 4062 days

#3 posted 07-02-2017 10:00 PM

I’m watching with interest. I’m so impressed that a physicist is interested in the real world troubles of making things work. I was trained as an engineer but always understood that ideas have to turn into actually make-able products. That you know how to stick weld is pretty impressive to me. I learned that method a long time ago and won several county and state fair prizes for my efforts but I am trying to master the wire welding these days. Forever the guy that just likes to make things.

-- Dr. Ken, Florida - Durch harte arbeit werden Träume wahr.

View Sodabowski's profile


2388 posts in 3434 days

#4 posted 07-06-2017 07:53 PM

I can relate to that Ken!

-- Thomas - there are no problems, there are only solutions.

View mafe's profile


12286 posts in 3690 days

#5 posted 07-10-2017 09:23 AM

How wonderful Thomas.
Invention is the mother of need… or…
Ok, just love for making things.
I usually say: ‘the result!, who cares!, the important is the process, the path wandered in deep focus and with imagination opening new doors’,
I use a angel grinder a lot when I weld. ;-)
Nice to see you my friend.
Best thoughts,

-- MAD F, the fanatical rhykenologist and vintage architect. Democraticwoodworking.

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