Build a Bicycle-Powered Band Saw

By William Kolberg
Published on May 1, 1985
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Except for the
Except for the "drive motor," my bicycle-powered band saw is similar to any standing band saw. No alterations to the bicycle are necessary, and it takes only a minute to switch from riding to sawing mode.
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To make a flywheel, start by lacing baling wire through the spokes of your band saw's lower bicycle wheel.
To make a flywheel, start by lacing baling wire through the spokes of your band saw's lower bicycle wheel.
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The table and blade guide supports are just pieces of flat stock welded to short tabs on the frame collars. The factory-made guide shown here fastens to a shoulder mounted perpendicularly to the end of the support.
The table and blade guide supports are just pieces of flat stock welded to short tabs on the frame collars. The factory-made guide shown here fastens to a shoulder mounted perpendicularly to the end of the support.
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Add cement and smooth it with a stick.
Add cement and smooth it with a stick.
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The upper wheel can be tilted on its horizontal axis by adjusting the threaded rods that are linked to the upper collars. The degree of tilt governs blade tracking, and band tension is controlled by the amount of collar lift.
The upper wheel can be tilted on its horizontal axis by adjusting the threaded rods that are linked to the upper collars. The degree of tilt governs blade tracking, and band tension is controlled by the amount of collar lift.
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You can save yourself a healthy sum by making your own blade guides rather than buying them.
You can save yourself a healthy sum by making your own blade guides rather than buying them.
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The finished flywheel.
The finished flywheel.

I’m a carpenter, and for years I assumed that the best way to cut wood was to plug in and “go with the flow.” For small jobs I’d still use my trusty handsaw, but for long, straight cuts I’d grab my two-horsepower circular saw and seek the nearest three-prong outlet.

That was OK when I was at a contract job site, but when I was working at home — especially through our mean, lean Wisconsin winters — it seemed as if a goodly share of my profits was being metered away to the local utility company while I was left with the crumbs.

And, of course, the cold season also kept me from my favorite pastime, bicycling. So, in order to fit one solution to these two seemingly disparate problems, I researched — then built — my “bandcycle” … a bicycle-powered band saw that makes accurate crosscuts, rip cuts, and miter cuts through soft- and hard-wood, and — with a simple blade change — saws through mild steel and aluminum as well!

Because the tool is made almost exclusively of common materials and salvaged bicycle parts, it cost me a good deal less than a commercial model with similar features. And though I’m not about to claim that it’s as convenient or powerful as an electric saw, it’s a heck of a lot cheaper — and even sort of fun — to operate.

Band Saw Basics

I didn’t reinvent the wheel when I pieced together my bandcycle. In fact, I just patterned my design after a conventional band saw. Typically, the lower wheel is held rigidly on its axis, while the upper wheel axle can be tilted a few degrees from horizontal to keep the blade from wandering off the rim.

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