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Cleaning up an old Wellsaw M1000 Horizontal Bandsaw, Part 2:

Wellsaw Horizontal Bandsaw

While I didn't necessarily need to get it all the way down to bare steel, in the case of the legs, I wanted to
because both castings needed attention. The first one because it had this crack just below the cross bar.
It had been cracked for at least two coats of paint, and so it was time to fix it right.

Wellsaw Horizontal Bandsaw

First, as always, I stop-drilled the end of the crack so it wouldn't spread further.

Wellsaw Horizontal Bandsaw

Then, with a cut-off wheel and a die grinder with a rotary file, I "veed" out the crack on
both sides to allow for better weld penetration.

Wellsaw Horizontal Bandsaw

Then it was a simple matter of stick-welding it up, gently and carefully, with "Muggy" rod,
which is specifically designed for welding cast iron.

Wellsaw Horizontal Bandsaw

Once it had cooled, I carefully dressed the weld down with the same grinders and a DA sander,
and smoothed it up to be almost invisible.

Wellsaw Horizontal Bandsaw

On the other casting, one of the legs had been broken entirely off, and badly welded back on, probably
with regular E6011 rod. The weld was ugly, but appeared strong and free of cracks, so rather than trying
to grind it all out and reweld, I simply dressed it down and smoothed it up for paint.

Wellsaw Horizontal Bandsaw

Fortunately no cracks or major porosity appeared, so it should be fine for now.

Wellsaw Horizontal Bandsaw

After that, it was time for paint. I'd managed to strip several parts and painted them all as a lot.

Wellsaw Horizontal Bandsaw

After two coats of my standard machine-grey alkyd enamel, I was ready to start assembling the frame.

Wellsaw Horizontal Bandsaw

And once painted, the weld is almost invisible.


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Information contained in these pages is for reference and entertainment purposes only.  Our methods are not always the best,
quickest, safest, or even the correct ones. It's up to you to know how to use your own machines and tools.
Keep your fingers away from the spinny blades o' death and you should be all right.