A properly set up bandsaw is essential for clean, accurate, and consistent cuts. With a few precise adjustments, you can transform a new or neglected bandsaw into a dependable shop workhorse. Below are the five key steps to dial in performance—plus a bonus tip for better dust extraction.
1. Square the Blade to the Table (Side-to-Side)
Ensure the blade is perpendicular to the table from left to right:
- Loosen the carriage bolt that allows the table to tilt.
- Adjust the stop bolt until the table is square to the blade.
- Retighten the carriage bolt and double-check for accuracy.
- Minor shifts can occur during tightening, so recheck as needed.
2. Square the Blade Front-to-Back
Verify that the blade is square to the table in the front-to-back orientation:
- Check for a gap using a square against the blade.
- If needed, insert shims (cut from aluminium can or metal shim stock) between the trunnion and the table at the rear.
- Loosen the table bolts slightly to insert the shim.
- Retighten and confirm the blade is now square.
This small adjustment is especially useful for joinery work where front-to-back alignment matters.
3. Align the Mitre Track with the Blade
Mitre track alignment ensures cuts follow the intended path without steering:
- Draw a reference line on plywood using a square from the mitre slot.
- Disengage blade bearings and make a freehand cut along the line.
- If the workpiece must be angled to stay on the line, adjust blade tracking.
To adjust tracking:
- Use the upper wheel's tracking knob.
- Clockwise moves the blade toward the rear; counterclockwise moves it forward.
- The blade’s gullet should sit on the crown of the tire for best results.
If needed, shift the table slightly by loosening its mounting bolts.
4. Align the Fence with the Mitre Track
Once the mitre track is aligned with the blade, set the fence to match:
- Bring the fence close to the miter slot.
- Check for gaps using reflected light or a straightedge.
- Adjust using the front and rear bolts until flush.
- Tighten securely once aligned.
5. Set the Blade Bearings
Proper bearing setup supports clean, controlled cuts:
- Side bearings should clear the blade teeth completely.
- Leave a paper-thin gap between the blade and the rear bearing.
- Thick blades may allow more clearance; thin blades require closer support.
- Repeat for both upper and lower bearing sets.
Bonus Tip: Improve Dust Collection with Kaizen Foam
Kaizen foam can dramatically improve dust extraction:
- Cut foam to shape and press-fit or tape it in place near dust ports.
- Seal common air gaps around the lower wheel housing or blade area.
- Clean the surface first using methylated spirits or TPS for better adhesion.
- Even small improvements in airflow direction lead to cleaner operation.
Once these adjustments are made, a bandsaw can be trusted to cut accurately with minimal ongoing setup. These steps improve efficiency, safety, and overall project quality.