Choosing the Correct Band Saw for the Job
Band saws come in two primary styles - vertical and portable. In theory, they are similar - both types use a continuous blade in the form of a band which rotates around two wheels. However, as is often the case, practice differs from theory and in this case, fairly dramatically.
Metal Saw
Vertical Band Saws
Vertical band saw are freestanding, although they may be set on a bench or have a stand on the floor. The blade travels vertically with the wheels arranged one over the other.
Vertical models can be used to cut wood or metal, depending on the blade installed.
In wood shops, these useful and hardworking tools can be used for resawing lumber - what I call scut work, or they can be used to cut intricate shapes - what I call decorative work, as well as everything in between. In terms of the process, because the saw is stationary, the operator is the one manipulating the material being cut through the running blade.
For decorative work, the degree of intricacy achieved will depend on the width of the blade itself (narrower will cut tighter curves), the nature of the material being cut - finer grained rather than loose, and the experience of the operator.
My personal experience with band saws comes from working in theater scene shops where the blades are generally set with wood cutting blades. In that kind of setting, band saws are generally used for decorative work and rarely for recutting lumber. In fact the myriad of materials cut with a wood blade run the gamut from wood to Styrofoam, ethafoam rod, and even objects such as books!
In a metal shop, a vertical model is likely to cut intricate patterns or possibly perform scut work such as cutting bundles of metal rods, or even lengths of conduit.
Again, because the saw itself is stationary, the material will be guided through the saw by the operator.
Portable Band Saws
A portable band saw is a hand held tool, wielded by an operator and generally used to cut stationary objects such as conduit. The operator is moving the saw itself rather than the material being cut. This is directly opposite how a vertical, stationary band saw is used.
Developed for use by contractors, these hardworking power tools are typically fitted with metal cutting blades and are used to cut conduit, steel stock, unistrut, threaded rod, and even concrete.
With the proper blade, a well equipped portable band saw is capable of cleaner and squarer cuts than a reciprocating saw. Again, with the right blade for the job, there will be fewer sparks and cleaner quieter cut. Because they are portable, time is saved since there is little to no set up time - the operator just moves the saw to where it is needed. Recently, cordless models are removing the limitations imposed by the necessity of running extension cords.
While coarse blades with fewer teeth will cut the fastest, they will also tend to rip and grab when cutting thin materials. As with most saws, choosing the correct blade is an important part of using the tool successfully.
A portable band saw is not one that you can pick up and use confidently, right out of the box. They are fairly heavy, weighing in between 13 and 20 pounds, depending on make and model. The key with successful cutting is to allow the weight of the saw to do most of the work, and not rush the cut.
Common Limitations of the Vertical and the Portable
Both types of band saws are limited by the width and depth of the throat. This limitation is called the cutting capacity and it restricts the actual size of the material that can be cut.
While there are similarities between the two types of saw, there are far more differences in HOW they are used and WHAT they are used for. They are definitely NOT interchangeable and it is important to educate yourself about which you may need for a particular job.