Tag Archives: shopsmith

Shopsmith Repairs: New bandsaw blade insert

The aluminum bandsaw blade insert was always a little bent and one day a piece of wood pushed it it into the blade. That twisted it all up of course, and it never really worked after that.

I’ve been using it without a blade guard for a while, which means lots of sawdust and little pieces of wood fell down inside the saw.

Tonight I was going to cut up a bunch of freshly cut crab apple wood, and I didn’t want (as much) wet sawdust piling up inside so it was time to make a new blade guard.

Bandsaw insert from a sawblade
Bandsaw insert from a sawblade

I got a pile of old saw blades with a ShopSmith I bought a little while back, and it looked like the blade was about the right thickness for the space.

I hammered the old insert flat and traced it onto the saw blade. Then I used an angle grinder to cut it out, and shaped it using a grinding wheel. I used a cutoff blade for some of the interior cutting, and then a file to round out the edges.

Closeup of the new bandsaw insert
Closeup of the new bandsaw insert

It sits about a millimeter below the surface of the table, and when I push it in it snaps into place and stays in place firmly.

I expect that this repair will last for a long time.

I’ve got to make another one for the Shopsmith jigsaw, but that’ll have to wait for another day.

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A Maple Spoon by Carli

My brother Benjamin and his wife Carli came to town and Carli made a spoon!

We started with a nice scrap of maple. After Carli drew the design she wanted we clamped it to the workbench and hollowed out the bowl. We used an old lathe gouge that has been re-ground to do this sort of thing. Once the bowl was roughed out we used a bowl gouge to smooth the inside and get the final shape she wanted.

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Once the bowl was ready we moved to the bandsaw on the ShopSmith where Carli cut out the spoon’s profile.

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With most of the the spoon’s profile cut, Carli suited up and moved to the belt sander for shaping and making the curves.

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We did the sanding outside. Even with the shopvac sucking up sawdust it still manages to coat everything in a fine maple powder.

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We used 80 grit sandpaper on the belt sander, so once the spoon was the right shape we moved to hand sanding with 120, 220 and 400 grit sand paper.

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Once it was finally silky smooth, she sketched “~Moore~” a couple different ways, then transferred the one she liked best on to the spoon handle. I carefully carved it out with a pocket knife and didn’t even slip on the rounded corners or lose the middle of the Os.

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Finally we finished it with several coats of danish oil. This piece of maple had some beautiful quilting in it and Carli did a fantastic job!

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Making a pie-bird rack

Caroline has a nice collection of pie birds. For our anniversary I made her a pie bird holder to show them off.

This board was cut from a walnut branch with a chainsaw and had been drying in my garage for several years.

I used a hand plane to do get it flat, and then the ShopSmith belt sander to get it smooth.

I drilled holes and inserted short dowels for the pie birds to sit on.

For the words, I found a font I liked and used Inkscape to layout the words as a mirror image. I printed them on our laser printer, then used a hot iron to transfer the mirrored image to the wood.

With the mirrored letters on the wood I used a wood burner to (very slowly…) burn over the letters to make it nice and solid black.

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For finishing I used about 10 coats of shellac. It dried quickly and made it nice and shiny.

To hang it I secured some blocks to the back with glue and screws, and attached D-rings to those blocks. I used washers and long screws to secure it to the wall, so that it can’t fall off without unscrewing the screws.

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