Wilmac bandsaw restoration.

[Retired]

Hi,

At last I finally made a start this morning on my Wilmac bandsaw restoration. I bought this bandsaw a couple of months ago through eBay collecting it from Derbyshire in our little Aygo on a beautiful summers day.

The saw was supplied without starter or motor which isn't a problem to me; with the saw home I soon had a 1HP single phase motor connected via a new taper lock pulley on the motor shaft and new drive belt. I've been using the saw until a couple of days ago when the band finally snapped this band being known to be worn when supplied with the saw so rather than simply buy more new bands I decided to restore the saw.

At first I thought the saw to run reasonably well even with the dull 1/4" band installed but whilst adjusting the guides I noticed the band was running "side to side" making correct adjustment a bit hit or miss at the side guides and I thought this would be due to the new tyres needing truing?

Stripping the saw was straightforward enough but I must say I exercised a lot of care; the main frame is cast iron so no rough work could be tolerated because such a frame would easily fracture? Before stripping commenced I did a visual inspection and to test my theory about the tyres I ran the tyres against a DTI (Dial test indicator) just for interest; sure enough the top tyre was out by ten thou and the bottom tyre out by 30 thou on circumference so neither tyre was concentric to the wheel axis which explains the side to side band tracking.

I was informed at the point of sale new bearings had been installed. With the wheels removed I could withdraw the two pairs of bearings which I did with the aid of a 10mm threaded rod; washers; nuts and a spacer taking great care not to force anything otherwise a buckled wheel would be the result. I was surprised to find a lot of play on the bottom wheel and once the bearings were removed I could easily slip the bearings back onto the shaft as they were very loose indeed; both bearings had been running loose on the shaft wearing the shaft to undersize by three thou; doesn't sound a lot but in engineering terms three thou is a big measurement.

The main shaft casting came away in two pieces this being made of cast iron which had previously snapped between two of the securing holes? Thankfully it wasn't me who caused the damage but it will rest with me to correct it? This casting is an interference fit into the saw frame so in effect the break won't affect the saw in any way but I'll see how I feel regarding turning a new casting? I'll need to turn a new shaft because I've never been a fan of knurling to bring a shaft size up? The shaft is fitted with a keyway so will be a bit more interesting to make; the shaft is 5/8" diameter so the Clarke lathe can handle this but the Clarke might struggle with turning a new main bearing casting; it's all good fun and whereas the broken casting and worn shaft would worry many it isn't a problem to me in fact adds to the challenge.

One big surprise for me was to find the main frame cast in two halves and bolted together? Perhaps Wilmac was only a small company with limited machinery otherwise it would have been beneficial to have the casting as one piece to save extra work and machining?

Out of interest it's easy for me to take for granted playing around with pulleys but for novices fitting a pulley to a shaft can be a headache. The pictures show the "taper lock" pulley I'm using on the saw drive shaft; these pulleys are readily and quite cheaply available in many sizes; they can be used with or without key for general workshop use because they lock onto the shaft. To install; the outer pulley is slid onto the shaft then the inner taper is slid on; two Allen grub screws are fully tightened locking the pulley to the shaft making installation very easy indeed. Anyone ever tried to remove one of these pulleys? For a novice using levers such as screwdrivers these pulleys are a nightmare to remove because after all they lock onto the shaft and even with both grub screws completely withdrawn the pulley usually refuses to budge? To make matters worse once installed it's difficult to see which way the taper fits. Please look at the picture of the pulleys; two grub screws lock the pulley in position but how many know that by simply using one grub screw and tightening it into the third hole this grub screw then releases the taper; neat idea which is brilliant once explained?

I'm not in a hurry but now I've started this restoration I plan to stick with it until completion. I'll keep adding notes as work progresses and for a change I've enjoyed myself today without moaning.

Kind regards, Col.

                               

[Radio Fixer]

Is this another Band Saw Colin? I seem to remember a black one that might become cream. I think you chould make restoring this sort of kit into a hobby as you obviously enjoy it so much. Could you break even once restored (discounting time) ?

I seem to have read some where that cast iron glues pretty good if not taking too much load? But you know you are going to make a new one as that's where the fun is

Gary

[Refugee]

That casting looks like it was flawed when it was new as the paint has migrated into the crack.
Is there another coat of paint under the existing finish?

[pwdrive]

The cast iron frame in two halves was common back then, cuts down on casting errors, normally when you split them there is a couple of locating dowels on the mating surface(s).

Lawrence.

[Retired]

Hi,

Thanks Gary. I restored a big Startrite bandsaw quite a while back which I used for a number of years and recently sold it to make space. I've mentioned this Wilmac before so possibly you remember it from then and yes it's going to end up with a shiny new cream/white machine enamel finish.

I doubt I would break even Gary on these restorations because having paid the normal going price for the saw or other machine then for one of these restorations parts need to be bought such as bearings; belt and electrical gear I would never make anything out of it; these restorations are a labour of love to me and I do enjoy restoring old cast iron machinery; I derive as much pleasure out of the restorations as in using them and usually I end up with a top quality machine built to last many years unlike the modern tinny rubbish put out for the DIY sector. This small Wilmac has an impressive capacity of 6" deep cut and a 12" throat whilst occupying a small footprint; it won't cut metal unless I gear it right down for speed. I bought some industrial strength super glue at a Rufforth event and perhaps this will glue the two casting sections back together again; at Rufforth the seller was demonstrating just how strong this super glue was; he had two very big steel hexagon nuts and he applied about six dabs of this glue to one of the nuts then rubbed the second nut into close contact; after only holding the nuts together in his hand for a few seconds he amazed those watching by throwing the nuts onto a hard floor; they remained firmly glued.

I'm not sure if the casting was flawed Refugee but yes something has contaminated the break line; cast iron is such fragile stuff to play around with and doesn't stand abuse; it's possible that the break occurred during assembly because the casting is quite a tight fit into the frame and if the set screws and nuts have been used to pull the casting in then this could easily fracture the casting? I've not yet got down to the paint job but the hammer finish is very thick indeed in fact it looks like it's been applied by a novice given the runs and curtains in its surface; its possibly the original finish because where the paint has chipped off there doesn't appear to be a different colour beneath?

I'd have thought a frame of this size would have been easy to cast Lawrence rather than play around with two castings; as you rightly say many casting joints are located with dowels (roll pins) these being added after the parts are perfectly aligned. I'm pleased you mentioned dowels Lawrence because I removed the big nut on the top wheel assembly thinking the heavy metal round support would then simply punch through but when I looked closely there is a locating pin and had a novice attacked this with a hammer the story would have ended immediately? It's so easy to wade in at full speed when stripping these old machines only to inflict a great deal of damage. As an apprentice I used to scrap lots of big machinery and at times this meant breaking up cast iron with a sledge hammer; it's strange how when I want to break cast iron using so much force it simply laughs at me but to tap a small casting such as this Wilmac could easily see it fall apart. The only difference between a good and bad restoration is usually a bit of time and patience?

This Wilmac isn't a big saw so shouldn't tax me too much during its restoration. The main areas for concern are the broken casting; the worn shaft then truing the tyres; the rest should be simple enough and such projects are well worth the time and trouble; it gives a nice buzz to be able to put one of these machines back into full service; much better than simply parting with a wad of cash for a new machine?

Kind regards, Col.

[Retired]

Hi,

In another thread yesterday I boldly stated that nothing other than an emergency would prevent me from spending time in the garage this morning. Get up have breakfast; don't switch on the football AKA BBC news; Bron would answer the phone; don't log on; say NO to callers wanting something for nothing or starting with "can you just", don't open any mail etc. etc in fact just get into the garage and blow the world?

Well; please blame me for today's terrific wind and storms. I had breakfast and fought my way into the garage at 7:30; I thought both garage doors would end up in Scarborough being buffeted so much by the howling wind; the car was driven out and parked on the drive then another fight had the doors closed; I was bitterly disappointed though if this was all the weather could throw at me for being so selfish as to want just a few hours of quality time on my own pottering in the garage; where was the cloudburst at least whilst I restored the Graduate I had both high wind and driving rain against the doors for days on end?

The wind was whistling and howling up the valley and at this time of the morning it was still a black hole outside as seen through the door windows in a picture below. With the CD player playing my favourite sixties songs I set about making the new main-shaft for the bandsaw. What joy it gives me to be able to switch lights individually right over where I'm working; the lathe was well lit up for a change. Because I'm converting the garage into my workshop lots of materials and tools have been given new homes so it took a while to get everything together.

       

I'm used to big industrial sized lathes and at first felt annoyed by the restrictions imposed upon me by the tiny Clarke lathe; this lathe is actually a beauty now with its new more powerful motor installed but having to use a spanner just to lock the tailstock in place; how quaint? I had just enough 5/8" Diameter bar stock (BMS) to make the new shaft of but it would take some fiddling to get it to run perfectly true allowing me to centre the tailstock end allowing a dead centre to be engaged; I wasn't in a hurry and finally with the bar running true I could start reducing it's size. First problem was the threaded end; checking the original with the thread gauges proved the thread to be 3/8" Whitworth; drat it I don't have a suitable die; the nearest I have is 9mm which is an odd size so then I wouldn't have a nut?

I could have drilled and tapped for a 10mm set screw but this would weaken the shaft at the bandwheel mounting? After a while I decided to reduce to the original thread size and hopefully will be able to buy a Whitworth die at Rufforth? Next was to reduce for the bandwheel; both these being easy tasks but a lot of care is needed because to blink would result in an under-sized and scrap shaft which I already had in the original. Again I had trouble finding a suitable end mill for milling the keyways so chose the nearest and will adapt the key to fit. I thought it very strange that the original shaft had a long keyway running right into where the bearings are located so I modified this adding just a keyway for the bandwheel. The original shaft also had a wide "flat" to engage the pulley locking screw? I'm using a taper-lock pulley but as I was already set up I added a keyway in this area.

The original shaft also had a shaped retaining collar which to a novice would appear part of the shaft it being turned from a single bar section; this collar was actually pinned very neatly by a taper pin which was punched out; again a novice might resort to pounding such a pin with a hammer and punch wondering why it won't release; many of these pins are tapered so if it doesn't release being punched one way turn it around and try again. I didn't have the correct taper drill so I drilled at the larger diameter through the shaft then drove the taper pin back home; I could have simply added a circlip groove but the collar is lightly loaded so saving me cutting the circlip groove.

With the collar located the shaft was once again set up in the lathe and the collar machined true.

As I looked at the garage doors from the inside I couldn't make out if it was just a waterfall or lots of snow bouncing from them? The bin men arrived so I had to break off to take the wheelie bin to the rear of the bungalow before it blew away. In spite of the weather I enjoyed my session in the garage this morning and now have a brand new shaft which was a pleasure to make even if the Clarke lathe was slow going. The home made keyway cutting jig was copied from a "YouTube" video so not of my design but it was extremely simple to make costing me nothing other than offcuts and it is highly accurate whilst being simple to set up and use. This new main shaft cost very little by way of money; I buy BMS in 24" lengths and like to have a small selection in stock so a 7" length would not cost a great deal but to have a new shaft made even one this small would bring tears to my eyes and a hole in my pocket; even a lathe as small as the Clarke will produce top class work with a bit of practice and patience. For anyone with a bit of lathe experience making a shaft such as this is most satisfying and straightforward to do; to a lathe novice though it is a different story?

       

WOW; a full morning in the garage without any hassle or interruptions; this is most rare. I knocked off for dinner with the intention of resuming work in the afternoon. We had dinner and as we looked out of the kitchen window we hear a very loud noise on top of the fierce howling wind and at first couldn't decide what the noise was; as I checked the front rooms Bron came to me and said something terrible has just happened? The noise was one of our huge conifers breaking; this conifer must be at least 50' tall; about ten years ago a very large section broke away in powerful wind landing right up the rear garden causing no damage other than lots of work to remove it. Now another large section had broken free but this time landed across the garden hanging up in other trees and laurels; I'm not going near this until the wind drops as it is highly dangerous and when I do eventually go to sort it out I'll take extreme caution; such trees command the highest respect.

I was about to do the washing up when the power failed; the electricity had been cut; a few moments later it flashed on again and at 12:55 it totally expired. Well I did say I seldom get any peace each time I want to enjoy some quality time in the garage; now the conifer is down demanding attention and a power cut prevents any garage activity; we waited and waited and found it galling that we could see power on at the other side of the valley; the wind was still trying to blow the bungalow over and it was the usual black hole; out with the candles and wait some more; at 4:40 the power finally came back on by which time it was fully dark outside scuppering any more garage activity for the day.

Every time I try to do something I want to do which I'm interested in something or someone spoils it but today because I was so determined and in the garage by 7:30am I succeeded in making the shaft so I can at least chalk today up as a success; what's tomorrow going to bring?

Bron and I feel very sorry indeed for the people who have lost their lives due to the storms today and for the thousands now without power or having to abandon their homes because of the high tide which is forecast to bring more misery with flooding; my problems are indeed small compared to what these people have to endure.

Just as I finished typing this we have been plunged into total darkness again with another power cut; only a few minutes this time but enough to fully wind the big key in my back to the limit. It knocked the clocks out again; and at first I thought I had lost this post but managed to retrieve it. The security lights are on but the street lights are out no doubt due to the extended power cut this afternoon; why these regular power cuts only affect our side of the valley is a mystery. Retirement isn't fun living here we even have to fight our way up the lane because the utility companies are forever digging the lane up; so far 18 weeks this session by Yorkshire Water. We love our bungalow but are not allowed to enjoy living in it. I'd better post this before it disappears yet again. (I've saved it just in case).

Kind regards, Col.

What a life; yet another power cut; will I live long enough to post? I'd better post and edit any errors once the electricity company gets its finger out?


               

[Refugee]

You need a wood stove in your workshop now as the wind is providing plenty of fire wood.

I planned to go to the Thursday flea market. I also was not beaten although many stall holders were.
I only spent 50 pence and watched the wind tip half the stock off a stall and onto the ground.
It was a novel way of keeping fit going into the wind with my head down.
Across the road they have no TV this evening.

[Retired]

Hi,

Thanks Refugee it's nice to know of another big spender like me?

Every time the weather turns for the worse the UK virtually grinds to a halt; look what happens every year when just one inch of snow falls?

Not the day I had planned at all for today; I expected to do the supermarket shopping early as I've already done then amble into the garage instead I'm ambling up the rear garden in a few minutes for a work out with the chainsaw. I mentioned today's activities to the lady on the checkout at our local Home Bargains store with the outcome that when I've cut the tree up she will visit to collect for her wood-burner; saves me carting it to the tip.

I'd love a pot belly stove in the workshop but simply haven't space for it; if I bought one though or even bought a kite it would never be windy again? It's very cold outdoors this morning but I'll soon get warmed up doing a bit of lumber jacking.

Time to get off my backside and I did enough moaning yesterday to cover for today; someday I will get into the garage?

Kind regards, Col.

[Radio Fixer]

You are right Colin, there are always folks worse off than us. So sympathy to those who were flooded. Of course some of this is due to bad planning: we have places whose names end in Weir and Spa whose waters long ago were piped deep underground. Now the areas above them get flooded when the rain is so severe and the ground is saturated and the pipes full to capacity. Similarly, what were once considered flood planes get built over ... Should put the houses on stilts really

Actually, a nice day here! I love wild weather and had a walk around the beach in sunshine. Walking into the wind was good exercise but with it was great fun getting blown along and running was a cinch.

The sea was big with great swells and shore dump but no windsurfers out: my mate had been out earlier with a tiny sail and board but 20 mins was all he could suffer due to the cold and wind chill. Me? I don't even think about it, I have a nice warm radio on the bench.

Anyway back on topic. The shaft is excellent and the method of milling the keyways is to a non lathe man very neat. It seems you can do all sorts with a lathe if you have the imagination to dream up a setup. Bit like routers in a way.

So another tree to take down. Anymore that size? maybe they should go to as a lot of wild weather is forecast for coming years. Of course the media loves to hype it up and always adds on 10 or 20 mph to the size of the gusts we ever get.

Keep laughing in the gloom

Gary

[pwdrive]

Good luck with the hang up Col, sometimes they are easy, sometimes they can be a pig, watch yer feet if doing a 45 deg slice or whatever to drop it off the stump.
Don't forget the laws of the seesaw....
Looks like the both of us on the firewood then, we've nearly run out here so a trip down the woods is imminent, was going to go down there yesterday but the wind was a bit iffy, been burning all that Eucalyptus we felled in the garden earlier on in the year, it's lasted about 6 to 7 weeks.

Lawrence.