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  1. #16
    Join Date
    Sep 2012
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    North Yorkshire UK
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    Hi Michael,

    I didn't realise that you called it a resistance welder ! Because the machine that he used had a pair of cables that went down to a transformer sat on the floor. He used a foot switch to operate it.

    I didn't see anything that I would call complex about it. Two cams clamping the blade to a pair of copper blocks and another cam pressing them together, all on a 8 X 6 piece of Tufnol or Paxolin board.

    I would have thought that it would be very easy to copy.


    Butt Welder.png
    Just three cams, two clamping the blade and one pressing the ends together. The brown is the Paxolin insulator and the blue is the support. The two power cables from the transformer are shown by the orange dots in the copper blocks. Only one side actually moved to force the blade ends together. The gap between the copper blocks was about 1/2" to 3/4" of an inch.

    The grinding jig, if you can call it that was just a curved steel section of a circle, probably of about two foot diameter and about the same length, about 50 mm wide, 1/8" flat bar. After welding and annealing, he just put the blade over it and held it down with his foot, ground it, flipped it over and did the other side.

    If I ever break a blade I would be very tempted to build a device like this, and I've got an old welding transformer to do it with !

    Oh I can feel another project coming on......
    Last edited by BaronJ; 9th Nov 2019 at 02:23 AM. Reason: Added Picture and information.
    Best Regards:
    Baron J.

  2. #17
    Join Date
    Nov 2017
    Location
    Geelong, Australia
    Age
    53
    Posts
    498

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    The ancient Thiel bandsaw I picked up a while back has a separate blade welder mounted to the side. No grinder though.
    As Baron says, it looks pretty simple. It's all contained on and in a metal box maybe 200x125x125 from memory.
    It's currently sitting in the back of the workshop at work until I sort out space/time for it at home.
    Happy to look more closely at it and grab some photos etc if you are interested in it's construction.

    Steve

  3. #18
    Join Date
    May 2011
    Location
    Murray Bridge S Aust.
    Age
    67
    Posts
    4,197

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    Found this simple looking device for grinding the weldment. For someone as skilled as you, it's a easy peazy job.
    https://www.youtube.com/watch?v=X8PcY7Fz7qk
    Kryn
    To grow old is mandatory, growing up is optional.

  4. #19
    Join Date
    Oct 2011
    Location
    Norwood-ish, Adelaide
    Age
    54
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    5,340

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    Quote Originally Posted by KBs PensNmore View Post
    Found this simple looking device for grinding the weldment.
    I haven't seen that but yes, that was the plan - something like the device featured (see option 2...)
    I would hope that anything I made would have a smoother feed action than that though.

    Those resistance welders are not all that complex, but I can do the welding bit. For me, the pain is the grinding. Even if I made up a resistance welder, I'd still have to grind it.

    Michael

  5. #20
    Join Date
    May 2011
    Location
    Murray Bridge S Aust.
    Age
    67
    Posts
    4,197

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    If you were to use a couple of the runners that you sold off, they would give you a smooth action, or make up a system like BJ did for his Tool and Cutter grinder using bearings, (all the same size though). Sorry BJ couldn't resist that one.
    Kryn
    To grow old is mandatory, growing up is optional.

  6. #21
    Join Date
    Sep 2012
    Location
    North Yorkshire UK
    Posts
    2,871

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    Quote Originally Posted by OxxAndBert View Post
    The ancient Thiel bandsaw I picked up a while back has a separate blade welder mounted to the side. No grinder though.
    As Baron says, it looks pretty simple. It's all contained on and in a metal box maybe 200x125x125 from memory.
    It's currently sitting in the back of the workshop at work until I sort out space/time for it at home.
    Happy to look more closely at it and grab some photos etc if you are interested in it's construction.

    Steve
    Hi Steve,

    That would be nice ! The guy that made my bandsaw blade warned me not to take any pictures when I got my phone out. Which considering where he is and some of the very nice gear he has in there doesn't surprise me.
    Best Regards:
    Baron J.

  7. #22
    Join Date
    Sep 2012
    Location
    North Yorkshire UK
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    2,871

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    Quote Originally Posted by KBs PensNmore View Post
    Found this simple looking device for grinding the weldment. For someone as skilled as you, it's a easy peazy job.
    https://www.youtube.com/watch?v=X8PcY7Fz7qk
    Kryn
    Hi Kryn,

    Is it me or is that grindstone running the wrong way ?
    Best Regards:
    Baron J.

  8. #23
    Join Date
    Aug 2011
    Location
    Melbourne
    Posts
    4,209

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    Quote Originally Posted by BaronJ View Post
    Hi Kryn,

    Is it me or is that grindstone running the wrong way ?
    That's kinda the idea I had for Michael, but use the similar clamping setup to sit it on your mag chuck and use the surface grinder. you could even use the same clamp setup to hold them in place when welding. Then transfer to the surface grinder.

    Simon
    Girl, I don't wanna know about your mild-mannered alter ego or anything like that." I mean, you tell me you're, uh, super-mega-ultra-lightning babe? That's all right with me. I'm good. I'm good.

  9. #24
    Join Date
    May 2011
    Location
    Murray Bridge S Aust.
    Age
    67
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    4,197

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    Found this on Google, a bandsaw blade welder in PDF format.
    file:///C:/Users/Kryn%20Buitendyk/Do...e%20Welder.pdf

    No
    To grow old is mandatory, growing up is optional.

  10. #25
    Join Date
    Oct 2011
    Location
    Norwood-ish, Adelaide
    Age
    54
    Posts
    5,340

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    Quote Originally Posted by KBs PensNmore View Post
    Found this on Google, a bandsaw blade welder in PDF format.
    file:///C:/Users/Kryn%20Buitendyk/Downloads/Bandsaw%20Blade%20Welder.pdf
    I'd be interested to see that (link does not work), but as I've already said,

    Quote Originally Posted by Michael G View Post
    ... I can do the welding bit. For me, the pain is the grinding. Even if I made up a resistance welder, I'd still have to grind it.
    It's the grinding that is the issue I want to solve

    Michael

  11. #26
    Join Date
    Aug 2006
    Location
    Melbourne
    Posts
    817

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    That link doesn't work because he linked it to a file on his computer.

    Here are some instructions for a bandsaw blade welder, not sure if it is similar to Kryns or not.

    http://pdfstream.manualsonline.com/b...1378d5a62f.pdf

  12. #27
    Join Date
    Sep 2012
    Location
    North Yorkshire UK
    Posts
    2,871

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    Hi Michael,

    Grinding Stand.png
    This is the sort of thing he used to grind the flash off the weld. Its about four feet tall and the part circle is about two feet across.

    It was just a long piece of angle Iron screwed to a wooden bench leg with the flat bit supporting the ends of the round bit level with the bench top.
    Best Regards:
    Baron J.

  13. #28
    Join Date
    Aug 2006
    Location
    Melbourne
    Posts
    817

  14. #29
    Join Date
    May 2012
    Location
    Tasmania
    Posts
    38

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    I MIG mine back together then use a cutoff wheel to gently dress the weld. It is easier with a cutoff wheel to avoid undercutting the band than it is with a grinding wheel. Technically not meant to axially load a cut off wheel but if your gentle...

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