How to MIG Weld a Band Saw Blade: A Comprehensive Guide

MIG welding a band saw blade is a crucial skill for any DIY enthusiast or workshop owner who wants to extend the life of their saw blades and save money on replacements. This comprehensive guide will walk you through the step-by-step process of MIG welding a band saw blade, providing advanced hands-on details and technical specifications to ensure a strong, reliable weld.

Prepare the Blade

Before you begin the welding process, it’s essential to thoroughly clean the ends of the band saw blade. This step is crucial for ensuring a strong weld. Use a wire brush, sandpaper, or a degreasing agent to remove any dirt, rust, or debris from the blade’s surface. Ensure that the mating surfaces are free of any contaminants that could compromise the weld.

Set Up Your Welder

how to mig weld band saw bladeImage source: Mig weld example

Choosing the correct wire diameter and gas type for your MIG welder is crucial for achieving a successful weld on a band saw blade. For this application, you’ll typically want to use a .030″ or .035″ wire diameter and a 75% argon/25% CO2 gas mixture. Set your welder to a DC electrode negative polarity, and adjust the voltage and wire feed speed to achieve a stable arc and good penetration.

It’s important to note that the specific welding parameters may vary depending on the thickness and material of the band saw blade. As a general guideline, thicker blades may require a higher voltage and wire feed speed, while blades made of harder or more brittle materials may require a slower travel speed to prevent warping or distortion.

Tack the Blade

Before making a full weld, you’ll need to tack the ends of the band saw blade together to hold them in place. Position the blade so that the teeth are interlocked, and use a few small, strategically placed tack welds to secure the ends. This will help ensure that the blade remains aligned and in the correct position during the welding process.

Weld the Blade

With the blade tacked in place, you can now make a continuous weld along the length of the blade. Use a back-and-forth motion to ensure even coverage, and maintain a consistent arc length and travel speed. The goal is to create a strong, uniform weld that will hold the blade together securely.

When welding the blade, pay close attention to the welding parameters, such as voltage, wire feed speed, and travel speed. These factors can have a significant impact on the quality and strength of the weld. Adjust these settings as needed to achieve the desired results.

Grind the Weld

Once the weld is complete, use a grinding wheel or belt sander to smooth out the weld bead. This step is crucial for ensuring that the blade cuts smoothly and rides well on the bandsaw wheels. Take care not to grind too aggressively, as this could weaken the weld or cause further distortion.

Test the Blade

Before using the welded band saw blade, it’s important to thoroughly test it to ensure that it’s functioning properly. Check for any warping or distortion, and make sure that the weld is strong and secure. If the blade appears to be damaged or compromised in any way, it’s best to discard it and start with a new blade.

Advanced Techniques and Considerations

While MIG welding is a common method for welding band saw blades, it’s important to note that other welding techniques, such as TIG welding or stick welding, may also be suitable depending on the specific type of blade and the available equipment. Additionally, some manufacturers may use specialized welding machines or techniques to create high-performance blades with unique properties, such as increased durability or resistance to wear.

When MIG welding a band saw blade, it’s crucial to use the correct welding wire and gas, and to properly clean and prepare the blade before welding. Failure to do so can result in a weak or unreliable weld, which could lead to blade failure and potentially dangerous situations.

Technical Specifications

The specific technical specifications for MIG welding a band saw blade will depend on the type of blade and welding machine being used. However, as a general guideline, the following specifications are recommended:

  • Welding Wire Diameter: .030″ or .035″
  • Gas Mixture: 75% argon / 25% CO2
  • Polarity: DC electrode negative
  • Voltage: Adjust as needed to achieve a stable arc and good penetration
  • Wire Feed Speed: Adjust as needed to achieve a stable arc and good penetration
  • Travel Speed: Adjust as needed to prevent warping or distortion, based on the blade material and thickness

It’s important to note that these are just general guidelines, and the optimal welding parameters may vary depending on the specific circumstances. Experimentation and careful monitoring of the welding process may be necessary to achieve the best results.


MIG welding a band saw blade is a valuable skill that can save you time and money by extending the life of your saw blades. By following the step-by-step process outlined in this guide and paying close attention to the technical details, you can create a high-quality welded blade that will perform just as well as a new one. Remember to always prioritize safety and take the time to properly prepare and test the blade before use.