Dominic's Jet Bandsaw Upgrade

A new 2-HP motor requires fabricating a new base.

SHOP OWNER: Dominic Greco
LOCATION: Richboro, PA

    About a year ago, I came across a brand new 2-HP 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 original motor in my 14" Jet Bandsaw for some time. After the flood, it worked well, but lately it was hanging up and stalling during the most simple of operations.
    I found the drawing for the 2-HP motor on Baldor’s Website, where I was also able to get a schematic diagram and detailed specs for this 2-HP motor.
    Due to the size difference between the old 1-HP motor and the new 2-HP, 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) motor, and then enclose it in a 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.
Dominic's Jet Bandsaw Upgrade

    I decided to make the cabinet from Baltic birch plywood, with hickory rails. I capped the plywood panel edges with 3/4" hickory or poplar where I could get away with it. Hickory seemed a good choice since I had some 1 1/2" x 1 1/2" spindle blanks lying around, and because this wood is hard enough to take the abuse a cabinet would see in my wood-shop. 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 one coat of sanding sealer, two coats of primer, and two coats of top coat.
    I had originally planned to have 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 footprint was way too small, which made the saw unstable. Using a Delta Universal Base expanded the footprint enough to limit this problem significantly.
Dominic's Jet Bandsaw Upgrade

    Designing the case wasn't very 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 was made from scrap sheet metal that was bent to a "Z" shape. The knob is a quarter-turn type used on industrial incubators.
Dominic's Jet Bandsaw Upgrade

    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 dust collection port was added some time ago to the lower wheel housing. I intend to connect both of these ports together with some flex hose and a 4-inch “Y” fitting.

    Thanks to some conversion and publishing help from Ellis, I am pleased to announce that the plans I drew up for the 14" Jet Bandsaw dust shroud are now available. You can download one part at a time, or the entire master drawing.

    The drawings should give you enough information to build one yourself. The only part missing is any mention of the attachment hardware. You’ll need one eyebolt that has an eye big enough to fit around the pin in the table. I used a 1/4" x 4" eyebolt with two 1/4" nylon washers, and a 1/4" wing nut.
Dominic's Jet Bandsaw Upgrade

    Since this motor's shaft was at least half as big as the one on the 1-HP motor, I needed to buy a new pulley. The 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, since 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 then multiplied the diameter by the ratio. This gave me the size of the smaller sheave.
Dominic's Jet Bandsaw Upgrade

    I ordered a link belt to replace the old V-belt. However, they sent the industrial grade version by accident (at no extra charge). Talk about a PITA to change size! Nevertheless, it's beefy and works well and I guess that’s all that matters.
Dominic's Jet Bandsaw Upgrade

    Later, I ordered a 220V - 30 CFM fan from Grainger. I calculated that the case had a volume of approximately 4 Cu Ft. Therefore, 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.
Dominic's Jet Bandsaw Upgrade

    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 in the process of setting up a shop in his garage and looking through some catalogs. I told him of the upgrades and offered him the bandsaw once I completed them. After several months of work on and off, I finally completed this project. 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 always looked out for my little brother Nicky and I (along with the rest of the kids). He also put up with my brother and I 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 has a leaf chipper he's fixing up for me!

. . . Dominic Greco



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