Thank you for all of the responses. I can see that my bandsaw is not up to the task. The tension adjustment knob is made of plastic and if I tighten it anymore it will more than likely break. Now I will start my search for a bandsaw that is capable of the work. I have been thinking about a larger bandsaw that is also capable of cutting metal. I saw this one at sears it looks like it will do the job and it fits the budget: Craftsman Professional 1-1/2 hp 15'' Wood and Metal Cutting Band Saw. Any thoughts?
Your decision will very much depend on your ability to compromise in one area or another.
Budget is always a concern, but when we start plunking down more than a few hundred (a grand or more), we need to make sure we're gonna stay satisfied with the investment for the long haul.
If you have the room, I would suggest going with two different saws instead of a combination model. The reason I say this is because the differences between cutting wood and metal entail more than simply changing speed and switching blades.
To obtain a straight cut in wood requires less blade tension than making the same straight cut in metal.
Quality cuts in metal require considerable tension because the cutting action on metal is different. Metal requires more force of feed, and the higher the feed force, the more blade tension needed.
A purpose-built metal-cutting bandsaw will have a different style of wheel to accommodate the higher tensions involved.
Everything about the saw will be more robust, from the frame itself, to beefier shafts, bearings, tension systems, and wheel construction.
This is not to say that the combination saws are no good; I am simply saying that you need to keep in mind that compromises are inevitable, and the more compromises we make, the further we stray from optimum cut quality.
For the combo models, the ones that really shine are the industrial models by manufacturers such as DoAll, RollIn, etc.
These guys have tire technology down to a science, and if you look at the weight of their models, you'll soon realize that mass is certainly not overlooked.
But then again we're talking an entry level price of $2k.
The Craftsman model to which you refer is the 22440. I have no experience with it, but a friend has the 22450, a larger model.
Grizzly has the G0621X, which is also in this same price range. Instead of using a gearbox, it uses a VFD for changing blade speed.
And, of course we have the various models by Delta, Jet, etc.
You have not stated your specific needs.
For metal cutting, unless you're
needing the extra capacity of a vertical saw for cutting large material such as sheet, etc., many people have done just fine with the small 4x6 horizontal/vertical models, or even the "portaband" models.
You would be surprised how many serious craftsmen have these as the primary metal-cutting saw in their shop!
For a couple hundred $, you can get set up with something specifically designed to cut metal. At this (entry) price level, it will probably require "tuning", and as with most products these days, will require upgrading to a higher-quality blade. But overall, they are really great "bang for the buck". Simply put, they are robust enough in design to accommodate most metal-cutting projects for the small shop.
My observation is this: For the same amount of $ spent on a combination model of dubious quality, you can get a metal-cutting saw that still gets the job done,
plus you can also get a
high-quality wood-cutting saw.
I have went the combination route before. I have converted existing saws, and have even built a few (talk about a project!).
It's great in theory- one saw for both applications. But I soon found out that, for the ones within most people's budget, the compromises are not worth the hassle.
Changing speeds and blades are not too big of a hassle, but cleaning the saw certainly is!
Other problems I have faced are flexed frames, accelerated bearing wear, broken shafts, wheels going eccentric, and rapid tire wear.
For the designs using a tire, tire wear is a bigger issue than most people think when cutting metal. Ideally, metal cutting will call for a "harder" tire (higher durometer).
If you do go with a combo model, try to get one with cast iron (or steel) wheels.
Also look at shaft size and frame design. You want plenty of strength here (weight of the saw is usually a good indicator).
Naturally, my suggestion of two different saws assumes you have the space for two saws, and you do not have large-dimension, metal-cutting projects.
Whatever you decide, Good Luck.
Rob