ends being joined by using a butt welder. Use the
1. Grind both ends of the band until they are
square with the band back edge. If you do not do this
carefully, the weld may not go completely across the
ends of the band and, as a result, the weld will not
withstand the pressure of the cutting. One easy
method to ensure that the ends of the band will go
together perfectly is to twist one end 180 degrees and
then place the band ends on top of each other. This
will provide a set of teeth and a band back edge on
both sides of the stacked ends. Ensure that the band
back edge and the teeth are in a straight line on both
sides. Carefully touch the tips of the ends of the band
to the face of the grinding wheel and lightly grind
until both ends have been ground completely across.
Release the ends of the band so that they assume their
normal position. Lay the back edge of the band on a
flat surface and bring the ends together. If you did the
grinding correctly, the ends will meet perfectly.
2. Set the controls of the butt welder to the weld
position and adjust the adjusting lever according to
Figure 4-16.--Butt welder-grinder unit.
the width of band to be welded. The various models
of butt welders differ in the number of controls that
must be set and the method of setting them. Most
models have a lever that must be placed in the weld
pedestal-mounted accessory. The butt welder also
position so that the stationary and the movable
makes inside cutting possible, since the saw band loop
clamping jaws are separated the correct distance.
can be parted and rejoined after having been threaded
Some models have a resistance setting control that is
through a starting hole in the work.
set according to the width of the band, while other
models have a jaw pressure control knob that is also
The following sections describe how to determine
set according to band width. Read the manufacturer's
the length of the band, how to join the ends in the butt
instruction manual before welding.
welder, and how to install a band tool in the machine.
3. Place the ends of the band in the jaws with
the teeth of the band facing away from the welder.
BAND LENGTH.--To determine the correct
Push the back edge of the band firmly back toward the
saw band length for any two-wheeled bandsaw,
flat surfaces behind the clamping jaws to ensure
measure the distance from the center of one wheel to
proper alignment. Position the ends of the band so
the center of the other wheel, multiply by 2, and add
that they touch each other and are located in the center
the circumference of one wheel.
of the jaw opening. Some models of butt welders
have interchangeable inserts for the clamping jaws to
The easiest way to determine the length of saw
permit welding bands of different widths. This is
band for a three-wheeled machine is to take a steel
done so that the teeth of the band are not damaged
tape, thread it through the machine over the wheels,
when the jaws are clamped tight.
and measure the distance.
4. You are now ready to weld the band. Some
Before measuring between the wheel centers,
welders require that the weld button be fully
adjust the upper wheel so that it is approximately
depressed and held until the welding is complete,
halfway between the upper and lower limits of its
while other welders required only that the button be
vertical travel. This allows you to take up any band
fully depressed and then quickly released. There will
be a shower of sparks from the welding action. Be