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Portable Bandsaw Stand

75551 Views 16 Replies 10 Participants Last post by  Netpackrat
I had a guy on an airplane building forum request pictures of this project, but it's easier to post pictures here, plus it's just as relevant to the Jeep forum as the other place, so I'll just send them here...

So, I have one of those Taiwanese metal cutting bandsaws that I bought for $200 ten or fifteen years ago... I mainly use it in the vertical position for cutting out small brackets and stuff from flat, including a lot of thin 4130 for aircraft and related work. Horizontally, a chop saw is usually better since the Taiwan unit doesn't cut very straight like that. It's a piece of crap, but it works, mostly. Biggest problem with it is it takes up a lot of floor space for what it does. My brother can use it in his bigger shop, to get it out of my way, but in the meantime I still need to have a metal cutting bandsaw in my shop.

The "easy button" that many of you are probably familiar with, is to buy one of the Milwaukee or Dewalt portable bandsaws, and then buy the benchtop mount from SWAG Offroad. The cost is reasonable, and it appears to be a quality product. The only problem I could find with it, is that all the saws which fit the SWAG unit share one flaw. The motor is located pretty poorly for maneuvering a piece of metal when you are cutting a part out of it. They work fine for cutting off structural beams, bars, tubing, etc, which is what the saw is designed for. I'm not really planning to use mine that way, so I wasn't satisfied with that.

The original Porta-Band saw was invented many years ago by Porter Cable (AFAIK). It was configured differently from the newer model saws, in that its frame was a single piece of cast aluminum, and more importantly, its motor was located in a different position, which allows for more cutting versatility in doing odd shapes. Porter Cable doesn't make the Porta-Band anymore, since they were bought out and their line of super high quality power tools has been replaced by a line of cheap Chinese crap that is sold at one of the big box stores.

That's really a tragedy for anyone who appreciates good tools, but the good news is that you can still buy a brand new Porta-Band saw; the only difference is that the plastic parts are yellow and it now says Dewalt on it instead of Porter Cable. I'm not sure of what corporate machinations resulted in this turn of events, but the Dewalt DW328 bandsaw is, as far as I can tell, the exact same thing as the old Porter Cable saw. It has a variable speed control so I can slow it down for doing things like 4130 and stainless, and speed it up for softer steel and aluminum alloys. It will even run off a 115V DC power source (think: Premier Power Welder) if you are out in BFE and need to cut metal.

The only problem with it is that it doesn't fit the SWAG table mount, so you have to build your own. I came across this video showing how one guy built his for an older Porta-Band unit, and I largely copied his design, making a few changes of my own.

Here are a couple of pictures showing both sides of my stand, without the bandsaw installed:

The vise-grip looking thing on the side is a drill press clamp that is used to secure the saw in place. I put a rubber pad on it where it contacts the saw. There is a plain 3/8" nut welded to the side of the frame for it to attach.

Some pictures with the saw installed:

It seems to work fine, although it isn't totally finished yet. I still need to find a piece of 4"x4" x 1/4" thick or so steel to make the cutting table from. Unlike the one in the video, it is going to attach to the stand rather than the saw, so I don't have to remove the blade guide just to remove the table. And I'm going to turn it around so the slot is to the rear. I'll have to remove the table to change blades, but I think it will be easier to use that way. I know a wider table is popular, but I have found the smaller ones to be easier to use when cutting out small or intricate brackets and you are maneuvering the work piece. Especially when wearing leather gloves. At some point I will probably add a foot control, also.
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nice work, thanks for sharing!
Appreciate it. I've been contemplating some idea for this. I like your idea. Thought about adding a small table top? Then you could also add a little fence or something.
Yeah, it isn't finished. I still need to obtain the right piece of steel to use for the table. I'm not going to bother with a fence, or miter slots. My taiwan bandsaw had provision for the miter gauge and I never used it in the dozen or more years that I've had it. The stuff I cut on a vertical bandsaw is usually irregular shaped, so I've never felt need of a fence.
Got the table finished a few days ago; here's the pic:

I need to get some longer screws to hold it in place, but this seems to be pretty good. To change a blade, I just have to remove the 4 allen head screws, and lift the table straight up and off. Then I can change the blade as normal, without removing the saw from the stand. That's 4"x4" 1/4" plate, and I cut the slot using my abrasive chop saw.
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Cool :) Does the table weigh enough to keep it steady without sliding, or is it bolted to the table somewhere?
I fasten it down with clamps. I could have made it heavier or bolted it down, but the goal was something that would do the job, yet would be portable and able to be put away quickly when not needed.
that's awesome! I want one...
Nice build, here is one for lazy people like me who aren't as industrious.
Nice build, here is one for lazy people like me who aren't as industrious.
Yeah, I saw those. I would have bought one, but the saws they take have an inferior geometry for vertical use.
The motor on the newer style saws that can be used in the SWAG Offroad stand is mounted vertically in the middle of the saw, and is right in the way of making longer cuts. The motor on the older style unit that I used, is mounted on the low end of the saw when positioned vertically, and below the plane of the material being cut. So, there is more clearance on the side of the blade, if you need to cut a longer strip off such as when making a longer bracket. It's just a more versatile setup.
Here is something that will help you cuts adjust the roller closer to the work.
I used this to cut a bunch of parts out of .080" 2024t3 aluminum yesterday and I love my new saw. I put it on the fastest setting with a fine tooth band and it breezed through it. It's much easier to use than my old Taiwan horizontal/vertical combo.
Pretty slick! Nice job!
Sorry to bump an old thread, but I didn't feel like making another with the same title to share my take on a custom porta-band stand. My buddy has the Swag setup for his Dewalt and I found myself at his shop using it frequently. I've had this HF band saw my wife bought me for several years and it keeps working so no point spending $300 for a new one to go with the Swag stand. I basically built this from scrap bits of steel I had laying around the garage so the cost was $0. Its not pretty, but it is very stable and has worked great for the past year since I built it.

Like the OP, I just clamp it to my table when I need it, and move it out of the way when I don't. Changing blades is a little tougher on this, but it can be done w/o removing the cutting table or the saw from the stand.

Some of the welds got ugly. We ran out of gas for the MIG and finished it w/ a stick welder which I had never done before. lol

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Necroposting to note that since I had to get some other stuff powdercoated, I took this to the coater at the same time:

I also polished the top surface of the table, although it doesn't show well in this picture.
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