Hello Everyone,
About a year ago, I came across a brand new 2HP Baldor motor that was destined for the dumpster at work. I snagged this bad boy faster than you could say "Bandsaw"!
I'd been rather unhappy with the motor in my 14" Jet Bandsaw for some time now. After the flood, it worked well. But lately it was hanging up and stalling during the most simple of operations. Due to the size difference between the old 1 HP motor and the new 2Hp one, I needed to design a new cabinet. I decided that this cabinet would feature some type of fan to help bring cool air into the motor. I could never understand why Jet would design a bandsaw with a TEFC (Totally Enclosed Fan Cooled), then enclose in sheet metal box. Thus making it difficult to get that cooling air! My 1 HP motor used to heat up quite a bit when resawing. Enough so that I could burn myself on the motor case if I wasn't careful.
Designing the case wasn't all that difficult. After taking the measurement of the old cabinet, I laid it out in AutoCad and designed a new one around the 2 Hp motor. The case would be as tall as the old one (mostly to allow the motor access door to be big enough so that I could get my hands in there to work), but would measure 19 1/4" wide x 17 1/8" deep. The latch shown holding the door closed in the picture below was made from scrap sheet metal that was bent to a "z" shape. The knob is a quater turn type that is used on industrial incubators.
The drawing for the 2 HP motor came right off the Baldor Web site. I was also able to get a schematic diagram and detailed specs for this 2 HP motor from Baldor's web site.
I also took the time to make up a new dust collection shroud that would fit around the lower blade guides. This idea is an adaptation of Jim Delaney's design that he posted on Badger Pond several years ago. The other disy collection port was added some time ago to the lower wheel housing. Both of these ports are intended to be hooked together with some flex hose and a 4" wye fitting.
Since this motor's shaft was at least 1/2 as big as the one on the 1 HP motor, I needed to buy a new pulley. Only problem was that the size I needed would not fit on that shaft. I ended up ordered a driver and driven pulley (V-Belt sheave) from McMaster Carr. Figuring out the size was easy. I had the old ones to go buy. I simply measured both and divided the smaller diameter by the larger diameter. This gave me the ratio I would need between sheaves to get the proper speed. I then looked up a sheave that would fit in the existing belt guard, and them multiplied the diameter by the ratio. This gave me the size of the smaller sheave.
To replace the old V-belt, I ordered a link belt. But I was sent the industrial grade version by accident (and at no extra charge). Talk about a PITA to change size! But it's beefy and works well. So I guess thats all that matters.
Later, I ordered a 220V 30 CFM fan from Grainger. I calculated that the case had a volume of approximately 4 Cu Ft. So this fan would change the air in the case about every 8 seconds. In order to minimize the dust intrusion, I also ordered the filters and housing that go with this fan. After I installed the fan, I tied the leads for both it and the motor to a terminal block. The wire then runs through the case and out to the existing pushbutton switch. Once you turn the saw on, the fan engages.
I decided to to make the cabinet from baltic birch, with hickory rails. The plywood panels would be capped off by 3/4" hickory, or poplar where I could get away with it. I decided on Hickory since I had some 1 1/2" x 1 1/2" spindle blanks laying around, and because this wood is hard enough to take the abuse a cabinet would see in my woodshop. I also decided to paint the case rather than stain it. I wanted it to look like sheet metal. So after assembly, the case got (1) coat of sanding sealer, (2) coats of primer, and (2) coats of top coat.
I had originally planned on having some type of integral mobile base feature with this new case. However, I found that I didn't like the way it performed in a mock up. The foot print was way too small. Using a Delta Universal Base expanded the footprint enough to limit this significantly.
Just about the time I was getting ready to put the case together, Woodworker's Warehouse announced that they were going out of business. With the help of my good buddy Art Silva, I "convinced myself" that I was ready for a new Jet 18" Bandsaw. I bought the new bandsaw and have been using it ever since. That sort of put this project on hold for a while.
After a time, I found that my big brother Joe was in need of a bandsaw. He was setting up a shop in his garage and was looking through some catalogs. I told him of the upgrades and offered him the bandsaw once I completed the upgrades. So after several months of on and off work, I finally completed this project this weekend. I imagine that my brother will find this saw to be all he needs.
I know what you're thinking. "He went and spent all that time on a bandsaw he's just going to give away?!" First off, this is my big brother. The guy who bought me more rubber band powered balsa wood planes(my favorite toy when I was 10) than I can count, and 100 Teenys (a type of Matchbox car) just caused I asked! Not to mention he's always looked out for me and my little brother Nicky (along with the rest of the kids). He also put up with me and my brother living in the same room as him for about 26 years! (I have NO idea how he managed to do that without totally loosing it!). Besides,.....he's got a leaf chipper he's fixing up for me!![]()
See ya around,