How to Braze Band Saw Blades

Band saw blades are generally expensive and are known to break regularly, depending on what they are used for. This can cause an issue for anyone who might be in the middle of a job; it can be quite an inconvenience having to order and then wait for the new blade to arrive before finishing a job. Thankfully, there is a solution to your band saw blade trouble. Brazing your band saw blades can not only save you money, but also increase the life of your blade tremendously.

Difficulty: Moderate

Instructions

Things You'll Need:

• oxygen/acetylene torch
• Striker
• brazing goggles
• safety glasses
• welding gloves
• brazing rod
• grinder with finishing wheel
• 2 large c-clamps
• small section of 4 by 4 lumber

1. Remove the band saw blade. At this time you will want to put on your safety glasses to prevent any flying debris from going in your eyes, Also, put on the welding gloves to protect your hands from the teeth of the blade. Now pull the broken blade slowly out of your machine.

2. Clean and flatten the band saw blade. Look at both ends and sides of the blade for any paint, grease, or foreign matter. If any exists, then clean the blade with your grinder. Start by softly grinding back and forth 2 to 3 inches on each side; be sure not to grind into the blade because this will make it weak. Now look at the blade to be sure it's flat. If the blade is not flat, then find a flat surface and tap it with a hammer until it's flat.

3. Prepare the blade for brazing. Using your small piece of 4 by 4 lumber and a workbench, place the blade together on top of the wood the exact way it broke, leaving a 1/16-inch gap to braze. Clamp the blade in place on the wood and to the workbench with two large c-clamps to prevent it from moving. You are now ready to braze the band saw blade.

4. Light the torch and begin brazing. At this time, put on your welding goggles to prevent eye damage. Locate the acetylene knob and open it counter clockwise a quarter turn; light the torch with your striker. Now that the torch is lit, locate the oxygen knob and turn it counter clockwise until the flame turns blue and is 3 to 4 inches in length. The torch is now ready to begin brazing. Heat the blade in a small circular motion until it is red hot. When the blade is red hot, melt the brazing rod onto the red hot blade while keeping the small circular motion; be careful not to heat the blade too much, as this will cause it to melt. When the braze has liquified and is uniform, shut down the torch by turning both acetylene and oxygen knobs clockwise. Let the blade cool.

5. Turn the blade and braze the opposite side. Once the blade has cooled, it is now time to remove the c-clamps and turn the blade to the opposite side. Once again, clamp the blade in place after turning. The braze will have melted through to this side and there will be residue from the wood it was clamped to; remove this braze and residue in a swift sweeping motion with the grinder. You are now ready to repeat the brazing process on this side of the band saw blade. When you are done brazing this side of the blade, let it cool for 5 to 10 minutes.

6. Clean and re-install the band saw blade. After a short cooling period, use the grinder to smooth the surface that was brazed; this will prevent the blade from getting caught on the material you are cutting with your bandsaw. You are now ready to re-install your bandsaw blade.