Resaw Jig for a horizontal bandsaw

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Project by HalDougherty posted 03-16-2011 07:51 PM 13443 views 4 times favorited 16 comments Add to Favorites Watch

I made this simple jig in about an hour to cut 4/4 lumber into thinner sections for woodworking projects. Cutting thinner green lumber can result in warping and twisting as the walnut, maple and cherry dry so a resaw is very important when your main product is laminated gunstocks. I started using a Rikon 10-325 bandsaw for resawing and it does a good job, but I needed a way to process more lumber than I could on my vertical bandsaw. I looked at a commercial horizontal bandsaw that is used by a local pallet company to make a jig for my sawmill. With some simple changes it could also be used with a vertical bandsaw.

In a few weeks, I’m going to saw some 6” poplar boards 1 1/2” thick to make siding for the old 2 story farm house I live in and use for my shop. The farm house is almost 100 years old and the siding needs to be replaced. This same jig will also make tapered siding if I raise one edge enough to give me two 6” wide boards that are 1/4” on the thin side and almost 3/4” on the thick side. After a trip through my router table to cut a 3/8” rabbit, I should have some nice looking poplar siding to replace the original siding. I’ll make some test pieces to see exactly how to cut the poplar before I cut 2000 bft of siding and mess it up… That’s my spring project… The late fall project will be hardwood flooring to replace the original pine. I’m not sure if quarter sawn white oak or hickory would look the best.

-- Hal, Tennessee

16 comments so far

View Sodabowski's profile


2388 posts in 3604 days

#1 posted 03-16-2011 08:14 PM

Hal, that’s VERY clever. Thanks for sharing.

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

View Div's profile


1653 posts in 3711 days

#2 posted 03-16-2011 10:10 PM

Hal, you are getting creative with that sawmill! Great stuff! Your jig is WAY better than the crappy contraption I threw together to do the same thing! One day when I find time I might steal your idea…
Wish my mill still looked that pretty!

-- Div @ the bottom end of Africa. "A woodworker's sharpest tool should be his mind."

View saddletramp's profile


1180 posts in 3409 days

#3 posted 03-16-2011 10:31 PM

Re: your fall project: Unless that pine flooring is really not salvagable, it is going to be awful hard to beat the look of that 100 year old pine once it is refinished.

-- ♫♪♪♫♫ Saddletramp, saddletramp, I'm as free as the breeze and I ride where I please, saddletramp ♪♪♪♫♪ ...... Bob W....NW Michigan (Traverse City area)

View Broglea's profile


693 posts in 3861 days

#4 posted 03-16-2011 10:34 PM

That’s a nifty little jig. Love it!

View StumpyNubs's profile


7806 posts in 3571 days

#5 posted 03-17-2011 12:23 AM

Great idea! I was going to put a riser block in my band saw to resaw wider boards. Instead I’ll just buy a $10,000 saw mill to do it! :) Over kill, eh?

-- Subscribe to "Stumpy Nubs Woodworking Journal"- One of the crafts' most unique publications:

View joshtank's profile


224 posts in 3744 days

#6 posted 03-17-2011 12:41 AM

very cool! i bet you’ll use that more than the skateboard with missing tucks and wheels.

-- Josh - Jacksonville, FL -

View SASmith               's profile


1850 posts in 3758 days

#7 posted 03-17-2011 01:18 AM

Great idea.

-- Scott Smith, Southern Illinois

View ous's profile


64 posts in 3426 days

#8 posted 03-17-2011 01:25 AM

Thanks Hal for the idea. I have had a skateboard in the shop for 7 years. Now I know what to do with it. I see your are enjoying your new toy.


-- Roy Montana

View STL's profile


68 posts in 3603 days

#9 posted 03-17-2011 03:58 AM

Awesome job Hal! I really like that. Thanks for sharing.

-- Dan Siggers, Alabama,

View steliart's profile


2895 posts in 3459 days

#10 posted 03-17-2011 09:37 AM

thats a very cool jig… thanks for sharing

-- Stelios L.A. Stavrinides: - I am not so rich to buy cheap tools, but... necessity is the mother of inventions !!!

View HalDougherty's profile


1820 posts in 4008 days

#11 posted 03-17-2011 01:12 PM


The main project I built the jig for is the make siding for my house. The estimates I got to have poplar siding put on from contractors in the area was from $20,000 up. The house is a two story farmhouse that’s over 40’ on a side. It’s going to take several big poplar trees to make enough siding to cover it. I would hate to resaw that much poplar on my Rikon. I resawed about 300 bft of cherry yesterday in about 15 minutes. A 25 hp bandsaw rips through 7” boards like a hot knife through butter! I cut the same amout of walnut & maple a few days ago in about the same time. Using the Rikon I only cut enough thin sections for the stocks I was making that week. Now I’ve got about a months supply of inner boards for my gunstocks.


I agree about the pine, but the farmhouse was rented for 30 years without very much upkeep. I sanded 1/2 the house to refinish the floors and they are in awful shape. There are cracks wide enough to see cracks in the subfloor. Plus dings big enough to hide a cat in. The farmhouse was built almost 100 years ago by one of the areas first doctors and no expense was spared in the construction. It’s beautiful inside. 10’ high rooms on the ground floor. It has walk in closets in the bedrooms and closets in each downstairs room. Most homes built 100 years ago didn’t have storage space like modern houses. It also has a built in china hutch in the dining room, french doors from the living room to the dining room and a beautiful hand made staircase to the upstairs. When it was built it didn’t have electricity, running water or bathrooms. There is a well house with a water storage area for milk and other perishables as well as a root cellar. (needs a new roof as soon as I cut some oak for trusses) I want to restore the house to the way it looked when it was built. I’ve redone the kitchen and bathroom as well as put on a new roof. My sawmill will pay for itself just cutting siding and flooring. Everything else I do with it will be profit.

-- Hal, Tennessee

View StumpyNubs's profile


7806 posts in 3571 days

#12 posted 03-17-2011 02:33 PM

Hal- I was saying it was overkill for ME to use a big sawmill for resawing. I wasn’t referring to YOUR situation. It was just a bit of humor :)

-- Subscribe to "Stumpy Nubs Woodworking Journal"- One of the crafts' most unique publications:

View HalDougherty's profile


1820 posts in 4008 days

#13 posted 03-17-2011 03:06 PM


It’s overkill for me too… I’m going to build some yard barns to help pay for the saw. I have road frontage on a road with a lot of traffic, so plenty of people will see them. Everybody around here has yard barns for sale, but they are made with thin plywood and are built as cheep as possible. Mine are going to be made from oak, poplar, and red cedar for the singles. (yep, I’m going to build another jig for cutting shingles) If I can make enough money from my gunstocks and other wood products, I can get some other equipment I need… Today’s task is to plane and sand the wood I resawed yesterday and glue up some blanks to carve. While the glue dries I’m going to make a coat rack for the entrance of my farmhouse with some of the cherry I use for gunstocks. Wood magazine printed plans for a wall shelf and towel rack a few months ago. I’m going to build it without the dowels and make the back slats full height to support brass coat hooks under the shelf.

-- Hal, Tennessee

View CPTjackarse's profile


9 posts in 3544 days

#14 posted 03-17-2011 04:17 PM

Cool jig! Don’t know much about siding, but I did do some flooring in our house. I put down 500 sq. ft. of quarter sawn white oak with walnut inlays around the fire place. It is alternating 3”, 4” & 5” widths. It does a good job of breaking up the wild grain. Danish oil finish brings out the ‘flecks’ the best.

View BlueStingrayBoots's profile


865 posts in 4773 days

#15 posted 06-06-2012 04:59 PM

i use a double drum sander after milling and drying, 36g. I prefer a sander over planer for the wood i mill, no green wood though.

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