I'm going to be making a portable bandsaw sawmill. It will be able to cut a slab 1200mm (4ft) wide and 8m long. The wheels will be old wheels off a mini they are 18.5" ( now im useing 27") diameter and will be powered by a 13hp petrol Kohler motor.(I have now got a 22hp Motor) We (me and my dad) will probably weld (silver solder) our own blades.
Here are some logs I will want to cut
Here is what I have designed so far
Here are some questions I have: ( The questions in RED
haven't been answered and the answer will be in brackets next to the question)
- Will we need to have a way to tension the blade or can we just pump up the tires? ( Can just pump up tires but probably should put a way to tension the blade )
- Can I just use water for blade lube? (Diesel is better it erodes at the sap and doesn't rust)
- Do I need to lock the saw head to the carriage? I will have a hand winch lifting it and then will I need to lock it? (Probably should because if the wire breaks (5.5mm Wire Rope probably won't break) but still should )
- Do I have to lift the saw head on the return or can the blade just scrap on the wood? (Yes probably should because if it's pushing the blade up a little bit it will pop off the blade)
-Can I use green stickers in between my wood once I have milled it or do I have to use dry stickers? (Yes but not ideal)
- More will be added soon
What I am using/doing
Blade Lube: Diesel
Bed made out of 125x65mm Channel
Carriage made mostly out of 125x50x3mm Box section
Blade Guides: Roller Blade Guides
Motor: 22hp Petrol
Here is my list of what I have spent so far https://docs.google.com/spreadsheets/d/1GpwtM4-dz2r4M73_X_YWPSkbwr4nfNiuKC6NIJb6lJk/edit?usp=sharing
Here is a Google Drive Folder of progress photos: https://drive.google.com/drive/folders/0B6NzuDmTB6DDY1ZQNWJFamR2VjA?usp=sharing
Here is what I have done so far (7/02/17)
I got this 125x65mm Channel for $10 a meter it had a little surface rust and little holes (6mm / 1/4") every 300mm 12". I had to fill them with weld and grind them flush and then buff them with a wire wheel on an angle grinder.
I then joined 3 channels and cut them down to 9.5m long, I welded 10 channel 1500mm long every 1048mm and then took it outside flipped it over and pushed it back in (didn't get photos of that)
Cutting all of those channels used a few cutting disks
Santa got me a length of 50x50x4mm box section, a length of 40x40x5mm box section, 4 lengths of 50x50x5mm angle iron and a 22hp V-Twin motor (Motor is still coming )
I cut a piece of that 50x50x4mm box section for my axle and drill 2 25mm (1") Holes 100mm (4") from the end to plug weld my stubs in
Here's a video of drilling the holes https://www.instagram.com/p/BOT429oAbHH/?taken-by=jaysybrandy
This is the drill I used to drill the 25mm holes
I then started on my draw bar. This is a bit of 75x75x5mm box section
Welded a bit of 80x10 flat onto the box section and added a gusset
In the other end, I welded a bit of 1" pipe for my pin to sit in
I welded my axle on. Those bits of box section extending off my axle are so my strong back can mount off there so it has a bit more strength
I put 1/2 of the strong back on and added some cross bracing.
I'll get a better photo of the strong back when it's flipped back over tomorrow.
I used some 20mm solid round for some cross bracing
I put cross bracing in the other side and on the axle
Pulled it outside and flipped it over
My dads friend who is a linesman gave us these weird bolt things.
They are for holding the insulator to the cross arm the thread is M20.
I cut the end off and welded an M16 nut onto the end also drilled a hole to put a bit of round bar through and welded 2 5/16th nuts on the end to stop it from coming out.
I also sharpened the end a little so it can dig into the log.
I cut some 1" galv pipe to fit in between my cross members on my bed for my log clamps.
Then I cut some 1 1/4" galv pipe 100mm (4") long and welded a 100mm long bit of 50mm box section with a 14mm hole drill in the middle corner
The hole is for an M16 Bolt and the pipe will lock when pulled back by the screw (like a pipe clamp)
I welded 2 5mm end caps and an M20 nut to one of a bit of 50mm box section 700mm long
This is how the log clamp will work the long 1" pipe will be welded to the bed.
The hole in the box section will have a nut welded on it.
For the log dogs, I cut 4 more pieces of 50mm box section 700mm long with a 45-degree angle on one end so the log can roll on it smothley and welded a end cap on each end to keep the water out and so the log doesnt grab on it.
I picked up some M16 bolts and nuts also a 5" flappy disk.
I then welded a M16 Nut onto a bit of boxsection for the log dogs to sit in
And welded it to the bed of the mill I will have 4 log dogs and 4 places for them to go and 2 log clamps and 4 places for them to go.
Welded the pipe to the bed rembering to put in the bit with the boxsection welded inn it
And it works !!
I might get a M20 Die to make the threads a bit longer.
I also welded the draw bar from the top side
My sister's boyfriend gave me 1m of Stainless M20 threaded rod and I brought one length for $59
I cut it into 8 pieces 250mm long
Then I drilled an 8mm hole in the end to accept a linchpin
Then welded an M20 Nut to one end so I can put a spanner on it and wind it down
The linchpin holds the foot on the way up and the nut pushes on the foot to lift the mill (probably should have put a washer in between the nut and bolt
The finished jack
I set the mill up perfectly level with a laser lever then made the angle irons level to that.
I had to join it in one spot
The wheels will run on the angle iron like this
I made 4 of these plates out of 5mm steel plate
And welded them to the end of the channel to stop the wheels (carriage) from falling off the end
Primed with grey primer
Then painted the main frame matt black
Then put the wheels back on
I will paint the jacks, dogs, clamps, drawbar and stuff a dark gray
To paint this I used about
4L of black paint + thinners
6L of gray primer + thinners
To get the mill to this point it took over 130hr
I cut two pieces of 150 x 50mm (6 x 2 " ) box section 1500mm ( 5ft ) long for my carriage, then put 5mm end caps on them.
Then welded 2 60x10mm with 25mm holes in them for my V wheels
The other side of the wheel mounts unbolt and has a little ledge to hook under my bed so that the carriage can't fall over
I then cut 4 gussets and 2 pieces of box section 2000mm long for my uprights
I also made 2 slides out of 5 x 50 mm ( 1/4" x 2" ) angle iron and 5mm ( 1/4 " ) plate
I bought a bandsaw blade for $105 from www.bandsaw.co.nz
I decided to use these bigger wheels that have an outside diameter of 700mm ( 27")
I will be able to get a little over 1200mm of cut
I backed my trailer part of my mill into the shed to work on my carriage
I then cut and notched a bit of box section for the top then welded it in
This was my first attempt at upside down welding (MIG)
I welded 2 braces onto the bottom and 2 on top to hold it while welding.
Lifted it off then welding in 2 corner braces
I then setup my saw head to weld in
I then made 2 gussets out of 5mm plate and welded them in
I have decided to use larger 6 stud wheels that are 700mm ( 27" ish ) outside butI have already welded stubs to a shaft for hubs that I have, so I need to make some hub spaces.
I started by cutting 2 200mm (8") out of 12mm plate
Our circle cutting jig for out plasma couldn't go down small enough so I had to free hand them. To true them up I drilled a 16mm hole in the center and held it on a piece of threaded rod on our "New Lathe"
I then bored the middle out to be a tight fit on the hub and then drilled 10 holes 4 to line up with my hubs and 6 to line up with my rims
I then turned a lip to be a tight fit on the inside of my rim
I then drilled my hole out to 14mm then tapped them to M16 and cut then cut 20 pieces of M16 rod 40mm for stubs
I also made 2 pulleys for my lifting my saw head
For my adjusting wheel, I made a slide out of 5mm plate
Then made a mounting plate to hold my wheel with u bolts (I made those holes into slots)