Horizontal Saw Setup¶

How to make your horizontal band saw cut square and true instead of making expensive angle iron.

The Problem¶

You cut a piece of 2" square bar 6" long. One end measures 6", the other measures 5-7/8". Sound familiar? Your saw isn't set up right.

Initial Checks¶

Before adjusting anything, check the basics.

Blade Condition¶

Inspect for:

Missing teeth
Uneven wear
Cracks
Excessive set wear

One bad tooth = crooked cuts forever

Fix: Replace blade if any issues. Don't try to "get one more cut."

Blade Tension¶

Most ignored, most important.

Proper tension:

Follow manufacturer spec
Usually 20,000-30,000 PSI
Buy a tension gauge and learn how to use it
"Tight as a drum" isn't a measurement

Under-tensioned:

Blade wanders, chatters
Crooked cuts
Poor blade life
Frustration

Over-tensioned:

Bearing wear
Frame stress
Blade breaks
Expensive repairs

Squaring the Vise¶

First place cuts go wrong.

Fixed Jaw Square¶

Check with good square:

Clean vise faces
Place square against fixed jaw
Check vertical and horizontal
Should be dead square to blade

Adjustment:

Loosen vise mount bolts
Tap into position with dead-blow
Recheck frequently
Lock down tight

Moving Jaw Parallel¶

Critical for gripping:

Close on parallel bars
Check gap with feeler gauge
Should be equal top/bottom
Adjust if needed

Common issues:

Worn vise screw
Bent moving jaw
Debris in slides
Never adjusted

Blade Guide Adjustment¶

Guides keep blade cutting straight.

Guide Position¶

Correct setup:

Close as possible to work
Both sides equal
Light contact with blade
Not pinching

How to set:

Back off all guides
Bring in until just touch
Back off 0.001-0.002"
Lock in place

Guide Types¶

Roller guides:

Support back of blade
Should spin freely
Replace if grooved
Keep clean

Insert guides:

Carbide or bronze
Support sides
Replace when worn
Critical for straight cuts

Ball bearing guides:

Premium option
Last longest
Most accurate
Worth the cost

Guide Alignment¶

Must be perfect:

Guides perpendicular to blade
Equal pressure both sides
No twist in blade
Check with straightedge

Checking Square¶

Multiple methods to verify.

The Quick Check¶

2-cut method:

Cut square piece
Rotate 90°
Make second cut
Pieces should match perfectly

If not square:

Determine direction
Adjust guides
Retest
Repeat until perfect

The Accurate Check¶

Using square and indicator:

Cut test piece
Check with precision square
Indicate across cut
Should be within 0.002" over width

Production Check¶

Stack test:

Cut 5 pieces same length
Stack them up
Should sit flat
No rocking = square

Common Adjustments¶

Blade Tracking¶

Blade walks off wheels:

Adjust tracking knob
Small movements
Run saw between adjustments
Center on wheels

Proper tracking:

Blade centered on wheels
Runs smooth
No wobble
Stays put

Feed Pressure¶

Hydraulic adjustment:

Start light
Increase until cutting well
Too much = blade deflection
Find sweet spot

Spring tension (manual):

Adjust for material
Consistent pressure
Not too heavy
Let blade work

Table/Bed Alignment¶

For angle cuts:

Check with protractor
Adjust stops
Lock securely
Verify with test cut

For straight cuts:

Should be at 90°
Check both planes
Adjust if needed
Critical for square

Troubleshooting Crooked Cuts¶

Cuts Curve to One Side¶

Causes:

Uneven guide wear
Blade dull on one side
Guides misaligned
Material moving

Fix:

Check/adjust guides
Replace blade
Secure material
Even feed pressure

Barrel-Shaped Cuts¶

Middle is wider:

Blade tension too low
Feed rate too high
Blade deflecting
Wrong blade

Solutions:

Increase tension
Slow feed rate
Check blade size
More teeth in cut

Tapered Cuts¶

One end thicker:

Vise not square
Material lifted
Blade worn unevenly
Guides need adjustment

Check everything:

Square vise
Support material
Guide alignment
Blade condition

Maintenance for Accuracy¶

Daily¶

Quick checks:

Blade condition
Coolant level
Clean vise jaws
Guide clearance

Weekly¶

Deeper inspection:

Check blade tension
Clean guides thoroughly
Verify square
Lubricate pivot points

Monthly¶

Full maintenance:

Replace worn guides
Check wheel bearings
Align everything
Document settings

Setup for Different Materials¶

Tubing and Structural¶

Special considerations:

Different wall engagement
May need to rotate
Support to prevent crush
Watch for twist

Bundle Cutting¶

Multiple pieces:

All pieces same length
Clamp extremely tight
Reduce feed rate
Expect some variance

Round Stock¶

Tendency to roll:

V-blocks in vise
Proper clamping
May cut elliptical
Check frequently

The Perfect Setup Sequence¶

Clean everything - Chips cause problems
Install good blade - Right TPI, sharp
Set proper tension - Per manufacturer
Square the vise - Both planes
Adjust guides - Close, aligned, proper clearance
Set blade tracking - Centered on wheels
Verify with test cuts - Adjust as needed
Document settings - For next time

Pro Tips¶

The Shim Trick¶

For persistent angle:

Shim one side of guide
Thin brass or steel
0.001-0.002" usually enough
Temporary fix

The Reference Bar¶

Keep a piece of precision ground stock:

2" x 2" x 12" typical
Use to check square
Store carefully
Worth having

Break-In Cuts¶

New blade or new setup:

First 5 cuts light pressure
Let everything seat
Check square frequently
Adjust as needed

When to Call It¶

Sometimes the saw is just worn out:

Worn wheel bearings
Bent frame
Worn beyond adjustment
Time for new/rebuild

But 90% of the time, proper setup fixes "unfixable" saws.

The Bottom Line¶

A properly set up horizontal band saw:

Cuts square and true
Blades last longer
Less material waste
No fighting the saw
Actually enjoyable to use

Take the time to set it up right. The hour you spend now saves days of frustration and piles of scrapped material.

Remember: That crooked cut gets magnified through every operation that follows. Start square, stay square.