DoAll DBW-1 Bandsaw-Blade Welder

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DoAll DBW-1 Bandsaw-Blade Welder

This highly specialized welder is really only useful for one thing: repairing broken bandsaw blades. It is also called a buttwelder, because the technical name for the type of weld it makes in the blade is a butt weld.

Basic Info

  • Ownership: TBD, best contacts are Dave Scholl, Dave Alvarez, or Steve Hermann
  • Location: The welder is currently disassembled on a workbench in the wood shop, next to the user storage area. These welders were usually installed inside the frame of a bandsaw, but this one was extracted from its bandsaw some time before it was brought to i3. Its long-term location is still TBD.
  • What it looks like:

bandsaw-blade welder photo The welder was originally made in the 1940's, and has been painted at least five times since then. Under the layers of paint, and an abundance of dirt, most of it appears to be original. The main contactor is labeled with the date "Sep 1941".

Manufacturer Information

  • Make/Model: DoAll DBW-1 Buttwelder
  • Part Number: S/N (unknown)

Documentation

not specified

Rules

  • Don't try to repair bandsaw blades yet, and please don't plug in the power cord.

Instructions

TBD

Other References

  • One particular i3 member, who is a bit of a wag, has been claiming to anyone within earshot that if you have two butts on or about your person, this piece of equipment will weld them together into one butt. Don't worry, nothing could be further from the truth.

Maintenance

TBD

Things that Need to be Done

  • Continue evaluation and repairs
    • Status of electrical testing/repairs
      • Light bulb hasn't been tested because light fixture and light wiring are in awful condition. However, since we are a hackerspace, we are required by international law to replace this 220V calendelabra-base incandescent light with some type of innovative LED, so we would have tossed it into the dumpster anyway.
      • Grinder motor runs quietly, appears OK
      • Annealing switch has been tested to work (0.6 VAC to the jaws), and its contacts have been cleaned
      • Welding lever supplies about 2.6 VAC to the jaws (at an unknown Heat setting)
      • Main contactor appears to be OK after the contacts were dressed
      • Heat selector switch appears to be OK after cleaning and lubrication
      • Weld stop switch appears to be OK after the contacts were dressed
      • All transformer taps appear to be OK when tested with 115V primary voltage
      • Most wiring will need to be replaced, so an electrical schematic diagram has been drawn
      • New insulators have been cut from 0.016 DMD sheet (Dacron-Mylar-Dacron from a motor shop, to replace the original waxed cardboard)
    • Jaw mechanism has been mostly disassembled
    • Grinding wheel is worn-out
    • Box is needed to cover the parts behind the front panel
    • Long-term location with 220V 1PH 30A power is needed
    • Etc.

FAQs

  1. Has anyone else ever repaired one of these old welders? Yes, someone rebuilt an entire 63-year-old DoAll Bandsaw, and rebuilt the welder as part of the project. Photos and written discussion are available on this thread in The Garage Journal. The URL is to page 5 of 26 pages, which is in the middle of the section that discusses the welder. The same author has made over a dozen videos of this project. They are available in the YouTube channel for APmachinist. Blade Welder Parts Repair is #14 in the Bandsaw Rebuild video series, and is one of several videos that discuss the welder. Note that the author's welder is model 1A, which is more recent than our model 1, and features different electrical adjustments.
  2. In the above-mentioned video, does the author take the viewer along on a loud motorcycle ride through the countryside into town, to an ACE hardware store to buy a plastic knob? Why, yes, he does! Interestingly enough, the same knob is also broken on our welder, so we may be looking to borrow a loud motorcycle for a similar road trip.
  3. Can bandsaw blades made with newer technologies (1950 or later) be repaired with this welder? Yes, if the annealing instructions from the manual for a newer model, e.g., the DBW-15, are followed.