Portable band saws have morphed into larger and smaller models, making them better suited for specific jobs.

Across the board, tool companies have taken the portable band saw to new levels in the last two years.

Smaller units and cordless models make them more attractive for scaffold or aerial lift work. Plus, new tool designs are more drop-resistant and make it easier to see the work piece.

“Users want a band saw that offers durability, performance and control,” says Kirk Reimer, DeWalt group product manager of grinding and metal-working tools.

“The tools are commonly used in two ways: construction cutting and correction cutting,” says Anthony Corwin, Makita product manager for commercial and industrial products.

“Construction applications usually involve cutting material on the ground in the open, in easy-access areas like a shop. Correction cutting takes place after the material is installed, often in confined spaces where overhead cutting may be necessary.”

“Choosing the saw depends on the material and size of what’s to be cut. If the work will mostly be in a vise, then a corded deep cut model is fine, but if you’re making cuts in place or overhead, a compact model may be easier to use. Many contractors have both,” says Melissa Marineau, Milwaukee Electric Tool group product manager.

To date, Milwaukee offers three main band saw models that can handle a wide variety of cutting jobs. Its 6232-6N deep-cut model can cut up to 4 7/8"x 4 7/8" material in a single pass; the 6242-6 compact band saw and the 2629-22 M18 cordless band saw can cut up to 3 1/4" x 3 1/4" material. DeWalt currently offers two band saw models designed to meet a variety of metal-cutting needs. Its DW328 model can cut up to 4 1/2" x 4 3/4" rectangular or 4 3/4" round stock, while its DWM120 unit can cut up to 5" round or 5"x 4 3/4" rectangular stock. It’s also working on its DCS370 compact cordless 18-volt model that it plans to introduce late 2010. The unit  features a centered handle for good tool balance, even in overhead positions and a heavy-duty, durable glassfilled nylon base and a 2 1/2" cutting capacity. It accepts DeWalt 18-volt Ni-Cd or Li-ion battery packs.

Corwin says that Makita offers two corded and one cordless band saws. The BPB180, which runs on Makita’s LXT 18-volt LXT Li-ion battery, and its corded 2107 model, can cut up to 4 3/4" round or rectangular material. The 2106 corded unit can handle up to 4 1/2" round or rectangular material.

Built for heavy-duty use

Because these saws are picked up, used, then set down often, they are also very likely to get dropped. In the past, those drops played havoc with wheel and blade guards on older-style tools. However, companies have changed tool designs so the saws can better withstand tool drops.

Milwaukee developed a composite shroud on its compact models that resists bending and absorbs drop shocks. Makita units feature a tool hook that makes hanging the tool more secure when it’s not in use and added protective rubber bumpers that help absorb the shock of drops.

To protect its band saws from drop shocks, DeWalt added a spring-steel shroud that’s over-molded with shock-absorbing material that protects the edge of the tool. It also added a built-in tool hook that’s easy to use but unobtrusive during cutting operations. Plus, DeWalt added a blade-tracking adjustment on the drive and tension wheels so users can compensate for slight wheel misalignments from drops, keeping the blade running true.

The transmissions inside the tools are beefier as well. The new DeWalt portable band saws have a double chain drive and double bearings on the blade guide to help the blade track true during cuts. The Milwaukee models are equipped with eight large ball bearings to keep the blade on track during operation. Makita has added dual bearing blade guides and an easy-to-use blade tightening lever for fast and easy blade installation.

Blade speed

Today’s units offer variable speed settings, which can help the user adjust blade speed to match the work at hand. “This is especially important when cutting stainless steel,” says Reimer. Slower cutting speeds will increase blade life and improve cut quality. The experts also point out that units with a variable-speed trigger allow the user to start a cut slowly then increase speed as the blade fully tracks in the cut.

Creature comforts

The new models pay much closer attention to making their use more intuitive and less taxing. The corded units weigh between 9 and 18 lbs., depending on size and capacity; cordless units tend to be smaller in size and weigh between 11 and 14 lbs.

Tool engineers have employed a variety of comfortable handle styles that make these models easy to hold and control. Milwaukee’s units have a T-style front handle that’s comfortable in most every position. DeWalt added an adjustable front D-handle to its DWM120 model, which Reimer says allows users to adjust its position to match the job at hand. Makita’s band saws feature a sweeping rear handle design that makes it comfortable to hold in many positions.

Newer models are incorporating additional lighting into the tools, which can help users see the cut lines more easily. “The LED light shines right on the cut line for good visibility.

At first, users said they didn’t think they needed it, but when they tried it on prototype saw models, they really liked it,” says Reimer. Makita’s 2107 and cordless BPB180 180 models feature twin built-in LED lights that illuminate the work piece; Milwaukee has incorporated LED lighting into its new compact band saw models.

All of the models feature an adjustable shoe that can be positioned for flush-cutting. Milwaukee’s compact models have tool-free shoe depth adjustment.

Band saw use tips

• Overhead work? Consider compact cordless units to make cuts. The units are smaller, weigh less and can get into tight spots without being tethered to a cord.

• Use two hands on the tool and wear eye protection.

• Adjust the shoe to best match the work piece depth.

• Before making the cut, position the work piece so it butts up against the tool’s shoe. That prevents it from jumping and vibrating in the cut.

• Allow the tool to gain power before touching the blade to the work piece, then let the tool take the blade through the cut. Don’t push or excessively force the blade through the cut.

• Be ready for the tool to cut through the work piece. The sudden breakthrough could cause you to lose balance or damage the work piece or the tool.