Fixing a 14” Bandsaw

Big bandsaws are expensive. So, I recently picked up a 14” bandsaw on Facebook Marketplace. It was one of those “needs a little TLC” kind of deals, which was exactly what I was looking for. The price was right, and the issues weren’t too intimidating: the tensioner was shot, and both blade guides needed some love. I was up for the challenge, and I figured this was my chance to get a little creative with repairs.

I’ve needed a larger bandsaw for some time now. I’d like to be able to resaw rough wood to the thickness that I need and then use the planer to clean it up. While this can be done on a tablesaw to some extent, a bandsaw is the right tool.

Starting with the Tensioner

The first issue was the tensioner. It’s a pretty important piece because, well, no tension means no straight cuts. I ordered a replacement, but getting it in place wasn’t as simple as I’d hoped. The new part didn’t fit quite right, so I had to make some space in the bandsaw casing. Enter the reciprocating saw! It was the right tool for the job, giving me a (rough) hole big enough to get that tensioner in place. Not exactly a precision job, but hey, it works.

*Cutting the tensioner hole larger so it can move freely.*

Tackling the Blade Guides

With the tensioner sorted out, I turned my attention to the blade guides. The lower guide was beyond repair, so I just went ahead and bought a new one. But the upper guide, I thought I could save—until I accidentally broke a bent piece while trying to straighten it. That set me back a bit, but rather than go through the hassle of finding a replacement, I decided to make my own.

Casting My Own Replacement Part

Now, this is where things got interesting. I decided to cast a new part out of aluminum. I used a lost-PLA method, which, if you’re not familiar, basically involves 3D printing the part in PLA and then casting it in aluminum. It’s a bit involved, but I was pretty excited to try it. Once the aluminum casting was done, I had a rough piece in my hands, and it was time for cleanup.

The Cleanup Process

The casting didn’t come out perfect, so there was a fair bit of cleanup to get everything looking right and fitting together. I rotated through a few tools—my reciprocating saw, a grinder, a cutoff saw, and a handful of metal files. With some patience and elbow grease, I was able to shape the piece, taking off rough edges and gradually turning it into something that could actually be used on the saw.

Making Square Holes with Round Bits

After getting the new piece into decent shape, I needed to drill some holes. I drilled a couple of larger round holes and then went old-school to turn them into square holes with a metal file. A bit tedious, but it got the job done. Finally, I drilled and tapped some holes to hold the guides in place, putting the finishing touches on the repair.

Wrapping It All Up

In the end, the bandsaw was back up and running. It took a little more work than I’d planned, and I had to get a bit creative along the way, but that’s what I love about fixing up old tools. There’s something satisfying about problem-solving your way through a project, even when things don’t go according to plan. Plus, I got to try out some new techniques—like casting parts—and I’m pretty happy with how it turned out.

If you’ve got an old bandsaw that needs some work, don’t be afraid to dive in and get your hands dirty. With a little patience (and a few spare parts), you’ll have it running smoothly in no time. And who knows, you might even enjoy the process as much as I did!

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