How do I Weld Broken Bandsaw Blades?

Written by jennifer patterson
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As with most tools, constant use of your band saw will cause the blades to become worn and eventually break. When this happens, there is an alternative to purchasing a new one. Broken bandsaw blades can be welded back together and function just as well as they did before the break occurred. This process requires a minimal amount of work. With the right equipment and technique, weld your broken bandsaw blades with little effort.

Skill level:

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Things you need

  • Band-saw welder
  • Cloth
  • Vice
  • Grinder
  • Welding gloves
  • Welding visor
  • Degreaser

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  1. 1

    Wear protective gear before welding your broken bandsaw blades. Put on a pair of welding gloves and a welding visor for protection.

  2. 2

    Apply degreaser to the broken bandsaw blades, making sure to put a thicker layer near the broken section of the blades. Leave the degreaser on the blades for one minute, then wipe the blade with a clean cloth.

  3. 3

    Place one of the broken blade securely into the vice, with the broken edge toward you. Smooth the edge using the grinder. Remove the first piece of broken blade from the vice and repeat the process with the second broken piece of blade.

  4. 4

    Place one end of the broken blade under the left clamp on your bandsaw welder, then place the other piece under the right clamp. Tighten both clamps to secure the blades. The ends of the bandsaw blades should protrude 1/4 inch out of the clamp toward the centre and should be fitted close together.

  5. 5

    Plug in the welding machine and turn it on. Press the welding button (the green button on the upper right of the machine). Hold down the button until one side is welded, then loosen the hand clamps. Flip the blade to the opposite side and weld it.

  6. 6

    Turn off the machine and remove the blades from the clamps. Test the strength of the blade to ensure that is strong. Let it cool thoroughly before using it.

Tips and warnings

  • A bandsaw welder is expensive, so consider whether it may be more cost effective to purchase new bandsaw blades, which start at about £5 each.
  • Do not use a welding machine around flammable substances.
  • Do not wear loose clothing or jewellery when welding broken bandsaw blades.

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