Wilmac bandsaw restoration.

[Retired]

Hi,

Thanks Gary. Yes the aluminium is pretty rough to the touch and would take considerable effort to bring to a mirror finish but as I'm re-painting the surface will give a perfect key for the new paint. If I had used soda then the surface would have not been affected at all whilst the original paint was being blasted away; the hard medium I'm using is very abrasive but much quicker and more suitable for my application than soda would be.

An open topped box would have been fine Gary but I'm fighting the dire weather and need to dash out and get blasting in minutes between high wind and rain; every time I wish to work outside I'm under pressure; I did exceptionally well this morning blasting for an hour and a half before having to quit by which time I felt absolutely frozen.

If we hadn't such a nice bungalow with outstanding views across the valley then I think we would have moved years ago because the weather is so unkind to us; The weather forecasters usually get the forecast totally wrong. Over the last few days we've been forecast high wind; heavy rain; hail; thunder and snow but the weather has just been a general pain as it usually is here. It could be worse because we could move to Big Al's old country on top of the world in Queensbury where I think it snows in mid summer? Am I far wrong Alan? Its an idea though Gary to have a large inverted box to place over me whilst I brave the short walk into the garage?

Kind regards, Col.

[Radio Fixer]

Yes! understood Colin. I was thinking of a collapsible box for later projects. Sort of hinged at all 4 corners so it pulls out from the flat.

Gary

[Refugee]

The second water filter may help to get rid of the blockages.
It will be easy to arrange a rainy day to go inside and fit it on.

[Retired]

Hi,

Thanks Gary. A collapsible blasting cabinet would be ideal and could be made to accept larger items where space is limited for a dedicated fixed cabinet; something worth thinking about but I've also been giving this whole blasting job some thought because I've had lots of problems as follows below.

I'm fully with you Refugee in your suggestion regarding sorting out the second air/water. Please see the following which I've simply copied from from another forum I've just posted on so pointless writing it out twice.

I've now had time to do more blasting so can update on the blasters performance.

I've never used a soda/hard medium blaster before and my blaster was brand new as was my 3hp compressor. I was advised to use the hard blasting medium which I bought two bags of (50kg).

Both success and failure; the positive side is that using the blaster has left the two main bandsaw components perfectly clean and ready for re-finishing once dusted off so in this respect it proved a success and did what it was designed to do.

The negative side however far outweighs the positive side on a number of counts. Firstly there is the cost of the equipment which in my case amounted to around £400 which I add I was happy to pay this being for the compressor; soda blaster; second air/water separator and 50kg of hard blasting medium. In use the second air/water separator failed immediately not even coming up to pressure due to a massive air leak so this was disconnected and still remains unused. Lots of safety kit needs to be worn; ear defenders because the compressor is very noisy; eye protection goggles; dust mask and gloves. Yesterday I spent most of the day blasting on our driveway; I had donned a tee shirt; shirt; jumper; body warmer and top coat plus the trousers etc; even so well wrapped up I could only stand an hours blasting before feeling too cold to carry on; just kneeling or crouching on the drive didn't generate exercise to keep me warm so I was at the mercy of the icy breeze coming up the valley.

I did however spend the afternoon in more comfort; the sun was shining raising the temperature a couple of degrees so I settled down to a session. The on-board air/water separator proved virtually useless and as a consequence the nozzle kept emitting a jet of water spray which in turn had blocked the valves; I was constantly either operating the blow off valve to clear the blockages or tapping the valves with a spanner which I found most infuriating. The compressor was running constantly under load giving around 2 Bar at the blaster during blasting. Blasting under these circumstances was incredibly slow; when the blaster worked as it should it was acceptable but the water ingress was slowing the whole job down.

Blasting by it's nature is a very dusty operation and this was borne out by the driveway resembling a dirty beach after even only a short blasting session. The debris from blasting clings to a wet driveway and surrounding area. If soda blasting and the soda gets onto vegetation it needs washing off otherwise the soda turns the vegetation brown. I used a wooden stick as a dipstick to determine blasting medium level in the tank but only after releasing air pressure. The heavy hose and nozzles are prone to wear so are consumables.

The bandsaw isn't big but the two main components must have taken over five hours to fully blast using at least 1 bag of hard blasting medium (£17 bag). Whilst blasting the aluminum component I could smell the aluminium which was being removed; this wasn't a problem but for a job requiring aluminium to remain shiny then soda must be used.

Without doubt the water problem proved the biggest obstacle but given how bad our weather is I don't have time to play around or investing in air/water separation expecting this blaster to be virtually plug and play without incurring lots of additional expense.

I don't regret in the least buying this blaster (a Christmas present in fact from my lovely Bron). I've always fancied owning a blaster and now that I've got one and gained some experience in using it do I keep it and sort out the water problem or sell it on? I could of course construct a blasting cabinet in kit form allowing the cabinet to be stored when unused; this would cut down on the dust problem. The water problem could also be resolved but at a cost yet unknown?

I like to experiment and having seen YouTube videos of home made soda blasters costing $15 I wonder if I could take this a step further. I'm thinking on the lines of using my very cheap air blow gun which is trigger operated for delivering air but add an additional nozzle after the air nozzle this nozzle being ceramic; between the two introduce a gravity feed hose for the blasting medium. If this would work then it would eliminate the need for the pressurized tank together with its many valves and also the problem of water ingress? A simple valve and reducing jet could be added to the gravity feed and the whole set up would cost very little indeed; the idea is based on an egg timer; as I say it's just a thought at the moment and I'm thinking aloud.

I'm unable to carry on blasting because its white over with a deep frost this morning so I think I'll postpone this bandsaw restoration for a short while and investigate the air/water separator problem which I can do in the closed and heated garage.

So far the negatives far outweigh the positives for me in blasting but for anyone with premises large enough to blast in perhaps the water ingress won't be such a big issue; I'm not in any way complaining just trying to give an honest account of my first blasting venture and I certainly don't wish to deter anyone from giving blasting a go because in spite of the cold conditions and the blaster problems it was most satisfying watching paint be removed down to bare metal with so little effort.

Kind regards, Col.

[Radio Fixer]

Well Colin. Thank you for breaking new ground, someone has to. And I don't want one.

A lot of drawbacks but a useful facility if you can set it up so it creates less mess and find a way around the water problem. (Sounds like me in the middle of the night !).

Keep having fun Gary

[Retired]

Hi,

Thanks Gary; I'm always keen to try new kit out.

I slipped up though because this morning I decided to investigate the problem of the second air/water separator and I don't mind admitting when I make a mistake.

When I was setting everything up and wanting to quickly get on with blasting due to having a window in the dire weather I attached this separator to the garage wall working in the usual doom and gloom. This morning I removed the separator from the wall to give it a good inspection and to power it from the compressor. I connected up and switched on the compressor but this time absolutely no air leak which I thought most strange because when I first coupled up masses of air was escaping?

Being stupid I had only connected it the wrong way around which of course was entirely my own fault but I sure suffered for it whilst trying to blast with the single on-board separator. If there are two ways to do a job I'll have to do the job twice?

I have however proved that the on-board factory installed separator simply isn't up to the job so hopefully now I've got my act together this second separator might improve things a bit? Watch this space for silly mistakes; saves you making the same ones?

Last night Bron and I arrived home and as we walked into the kitchen Bron switched on the tumble drier only to hear it hum? I switched off then switched on again to blow the 13A fuse. Lovely timing this to wind me up just as we walk into the bungalow; I changed the fuse then blew the second fuse which is something most of us do. After tea this job was now bugging me and I knew if I didn't fix it I would only lay awake in bed with it on my mind. As usual it was pouring with rain outside and a black hole making me wish I could do many trips down to the garage just for the fun of it. Instead I went into the workshop collected screwdrivers and pliers and set about the repair. I love working on white goods with their multitude of self tapping screws. Ten minutes later after a capacitor change it was running again.

Today has been like a rare summers day apart from it being cold so no time to play around enjoying myself. I set about blasting all the grit out of the garage using the air blow gun; with dust mask in place I soon had a nice dense fog leaving the garage. Once done no time to waste; up into the rear garden and remove yet more storm damage this time a long trunk from another conifer; cut up; load into car then visit the local tip. There goes my enthusiasm to work on this bandsaw; I wonder what joys will await me tomorrow?

World war three has just broken out. This morning I washed a pile of dirt on the driveway to find the car under it making a decent job of it. As I set off to the tip with the clean car I ran into a stream running down Rowley Lane 100 yards from home. Yorkshire Water have just spent over 18 continuous weeks digging the lane up and the surface has only been down for about a week so there goes my clean car. As I say war has just broken out; the water has been turned off and now it's just been turned back on; what a racket I needed ear defenders as the air hammers set in; where the heck can I get some peace in retirement?

Kind regards, Col.

[Retired]

Hi,

After a poor start to the day I finally stopped moaning and got off my backside determined to spend some quality time in the garage. First job was to find the benches so I had a good clear out of junk and then tidied up.

I've never been as undecided as I am about whether to sell the blaster or not? The blaster does a top job at cleaning metal but during my short use I found the blaster to be both friend and enemy; What a mess it made in the garage with grit everywhere even though I was blasting on the driveway; the blasting media gained access into my dust mask and worryingly into my safety goggles; these goggles are the standard plastic type with tiny vent holes along the top and the blasting media obviously was finding its way in but fortunately not into my eyes or the blaster would already be history. I don't really deep down want to part with this blaster but then I can't put up with the dirt it creates whilst using the hard blasting medium. I am also concerned about inhaling the blasting media even if only in small doses. I could prevent most of the dirt entering the garage simply by closing the doors onto the pipes whilst I blast in the driveway; sweeping the driveway isn't a major issue as long as it is dry. Last night I was very concerned about the air/water separation problem knowing the blaster tank inner cap and inner filler neck to be wet; I assumed this water was also invading the blasting media?

Intending to get the blaster ready to sell I swept the garage floor then tipped the blaster up to empty the blasting medium from its tank; I was extremely surprised to watch the medium form a large pile on the floor and it looked bone dry? Whilst blasting the nozzle kept issuing a jet of water and then I had to either tap the valves with a spanner or open the blow-off valve to get it blasting again and it is this nuisance of blockages which is annoying me the most. I feel very tempted to hook up the second air/water separator but this time couple it correctly then try the blaster using soda? If soda gets onto the machinery in the garage it won't do any harm and also soda is of little danger to me unlike the hard blasting medium I've been using. Decisions; decisions?

I've had a most enjoyable day in the garage and made progress with paint removal; I didn't want to get everything and myself covered in blasting medium again so I resorted to hand scraping. The two band-wheels were like the rest of the bandsaw covered in very thick hammered enamel and to be honest I wasn't looking forward to removing this paint at all; knowing how long I had already spent using the blaster I thought I would at least try using a scraper. I use an old worn engineers hand file fitted with handle (never ever use a file without handle) this I sharpen across its end taking seconds on my double ended bench grinder.

It was wonderful to have so much room on the bench and I was amazed just how easily this scraper popped the thick paint off the aluminium band wheels. To get right into tight corners I used a craft knife and the job turned out much better than ever I thought it would all in the comfort of my newly refurbished garage/workshop.

The garage/workshop is coming on a treat and what a pleasure it was to work on benches with plenty of space; well lit and to be warm for a change in fact I felt hot whilst scraping even without heat on. I'll need to install the new bearing housings before painting the bandsaw and this involves aligning both band wheels so should be fun but once the bearings are sorted I can remove the wheels without difficulty knowing they will align once re-installed. If more days go like today I might even stop moaning?

Kind regards, Col.


                               

[Radio Fixer]

Seems like it has to go Colin IMHO. But its not a failure, knowledge gained and another experience.

Maybe you wont drop you too much on Ebay, all cleaned up ...

What do the neighbours think of it or haven't you asked them? Noisy compressor running for long periods would upset lots of folks + did any grit go over their side?

Even if I hadn't spoken to them I would be concerned and it would be another -Ve against it.

Hope I'm not being a killjoy ... just picking up on your vibes.

Gary

[Retired]

Hi,

Thanks Gary for your reply and concerns raised.

Neighbours both sides are no problem and as we are detached the noise I produce is somewhat diluted by the time it reaches neighbours houses/bungalows; I did ask our immediate next door neighbour if my compressor was a nuisance to her and she replied she doesn't hear it.

A few years ago I visited our neighbours directly across purely out of courtesy to explained a guy was travelling over from Ireland with his Land Rover and big trailer to collect the Colchester lathe I had just sold him. It was the son of about 50 years of age who answered the door and he simply said OK then closed the door. I also visited other close neighbours doing the same.

The guy arrived and as I had mounted the lathe on wooden skids it was easy to winch onto the trailer; as the guy was securing and covering the lathe this 50 year old son arrived in his mothers car and I couldn't believe when he drew up to the rear of the trailer on his side of the road and locked the car even though the driveway at his parents house holds three cars and was empty; just at this point another neighbour a lady (?) who lives at the head of the cul-de-sac drove on the street and obviously could not continue due to the street now being completely blocked; this neighbour looked at us and then started to sound the horn of her car; this son then said to me "can't she drive" at this I walked away in disgust so regarding the neighbours directly across I'm now extending the same courtesy they extend to me. These particular neighbours directly across think they own the street and the father a few weeks ago asked the daughter-in-law of our new next door neighbour to move her car which was parked across OUR drive whilst our new neighbour moved in that day; items were being carried into the bungalow from the parked car and Bron and I certainly had no objection to the car across our driveway. Reminds me very much of the Doctor's family on "The Burbs". I try my best to avoid this miserable family and I won't be doing anything silly either; some people are well left alone.

I'm still undecided Gary bout selling the blaster because if I jump in and sell it now I might regret it shortly; each blasting job I do with it the blaster gets cheaper and cheaper. If it doesn't snow I might have another visit over the top to Oxenhope and buy a 25kg bag of soda then if I do decide to sell the blaster after trying it with soda I'll know I've fully tried using it. At the moment I'm dithering which is unusual for me.

Out of interest Gary and regarding noise along our street; these houses and bungalows are extremely high maintenance and there are many tradespeople employed by our neighbours many using big power tools like industrial stone cutters sending up clouds of dust; Bron and I accept this because after all these neighbours are adding value to the street which can't be a bad thing? Bron and I get along well with our neighbours apart from the ones directly across from us which is a shame because ignoring the weather it's lovely living here in our dream bungalow.

I'll keep updating the thread with any changes or progress. I'm now settling down and hopefully will be able to spend more time in the garage; I'll admit my enthusiasm left me for a few months because of problems around the bungalow but now I'm keen to get on with this bandsaw restoration then hopefully spend some quality time playing with all my new toys including the Graduate lathe.

Kind regards, Col.

[Retired]

Hi,

What a lovely day I've just spent in the garage working on this bandsaw. It was very cold this morning even with the fan heater switched but after dinner I warmed up nicely.

First job was to install both new bearings to the bottom drive band-wheel. This looks so easy that a child could do it until it's realized that both band-wheels need to be coplanar (aligned). The new bearings are in cast iron housings and being cheap they didn't want to behave. The actual bearings are installed into a spherical sleeve this sleeve in turn installed into the outer cast iron housing. Good quality bearings ensure this sleeve is free to give lots of adjustment thereby aiding shaft alignment but the sleeves on these two were extremely tight indeed. I tried applying lots of oil and nipping each housing in the vice to insert a shaft hoping to free them up a bit by using the shaft as a lever but they remained very tight.

The housings were to be mounted back to back sandwiching the bandsaw case but it was impossible to align both band-wheels because I couldn't get fine adjustment in fact it was proving very difficult to get the wheels anywhere near so a new plan of attack was called for.

I drilled two holes through the outer face of one of the housings this being tapping size for 5mm. The housing was accurately aligned then masking tape was added around the housing attaching the tape to the bandsaw case giving a reference to work from. With this housing aligned I used both holes as a guide and drilled through the bandsaw casing freehand using the big Bosch drill; cast iron is a dream to drill into. The new holes in the casing were then tapped at 5mm and the housing holes opened up to 5mm clearance. Now I could securely align this housing using two 5mm x 18mm socket machine screws.

Before permanently securing this housing I mounted both housings back to back on the shaft taking advantage of the sleeve stiffness then gently installed the first housing tightly securing it into position with the two socket screws; taking care not to disturb the bearings the second housing was loosely installed then aligned by inserting the shaft then the housing was tightly secured by the four through bolts; washers and nuts; a wooden straightedge confirmed band-wheels were at last fully aligned. This sounds long winded but it was a problem to solve which on first glance appeared easy? I could now pull the bottom band-wheel and shaft clear just leaving the bearings in place; this was a positive step forward and hopefully once the saw is fully assembled the band will track OK?

I can now turn my attention to getting everything ready for the paint job. The hammered enamel had been very thickly sloshed on everything. Hammered enamel is supposed to be tough paint but then I come along with my hand file sharpened at the end to form a scraper and this paint flew off the metal. Much quicker than using my blaster or chemical stripper; eye protection is a must because when I say the paint flies off I mean it; it comes off in a shower with each push of the scraper; the item being scraped needs to be pushed against something solid to prevent it sliding around but it's most impressive to see paint removed this way. Awkward corners were attacked with a Stanley knife and again personal safety is an issue to avoid slicing into flesh. A rub down with abrasive paper and more items are ready for painting. All in all a rewarding day which I've enjoyed. I can spend tomorrow in the garage so at last this project is now moving forward.

Kind regards, Col.