Resawing lumber allows you to cut thicker stock down to thinner dimensions that can then be used for projects like drawer sides, bent laminations, veneers, and more. A sharp bandsaw makes clean, straight resawing cuts, but in order to get accurate thin slices you need a proper resaw fence. A good resaw fence is adjustable, tall, and most importantly, parallel to the bandsaw blade.
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What is Resawing?
Resawing refers to cutting a board along its thickness rather than its width or length. The goal of resawing is to cut thicker lumber into thinner boards. For example, resawing a 4/4 (1 inch) board into two 2/4 (1/2 inch) boards. Resawing can be done with a bandsaw, tablesaw, or hand saw, but a bandsaw is the most efficient tool for resawing.
Why Resaw on a Bandsaw?
Bandsaws are designed specifically for resawing. The two main advantages of bandsaws for resawing are:
- Narrow blade kerf – Bandsaw blades are very narrow, usually around 1/8″ thick. This allows you to maximize the wood yield from each cut. A tablesaw blade kerf may be 1/8″ or more.
- Straight cuts – The flexibility of the bandsaw blade allows it to cut straight and true through the wood without deflecting. A rigid tablesaw blade often wanders when resawing.
Additionally, bandsaws have a tall cutting capacity making them well-suited for resawing thick boards. The key is adding an adjustable resaw fence to keep the cut consistent and perpendicular to the table.
What Do You Need for Resaw Bandsawing?
In order to resaw successfully on the bandsaw, you’ll need the following:
- A good bandsaw – Look for a 14″ or larger bandsaw with at least 3-5HP and 12″ cutting capacity.
- A sharp blade – Use a bandsaw blade with at least 3 tpi. Many resaw blades have 4-6 tpi.
- Coolant – Either a mister or brush and liquid coolant is recommended for smooth cuts.
- A tall resaw fence – Essential for keeping the workpiece perpendicular to the blade when cutting.
In addition to these necessities, a bandsaw sled can be helpful for resawing smaller or irregular stock. Now let’s look at how to build a proper tall resaw fence for bandsawing.
Design Considerations for a Resaw Fence
When designing and building a resaw fence, here are some key factors to consider:
Height
The fence needs to be tall enough to support the full height of the workpiece, plus a few extra inches above and below. Most resaw fences are 18-24″ tall or more.
Adjustability
Having an adjustable fence allows you to fine tune the distance from the blade based on the thickness of cut you want. Aim for 1/32″ or finer adjustment capability.
Stiffness & Perpendicularity
The fence should be flat, stable, and perpendicular to the table for straight resawing. Using thick materials like MDF or plywood helps minimize flexing.
Workpiece Support
Bearings, rollers, or non-stick surfaces along the fence face support the workpiece during the cut and reduce binding on the back of the blade.
Dust Collection
Having dust collection integrated into the fence helps improve visibility and reduces mess.
Keeping these factors in mind will help guide your design and material choices for the fence.
Making a Resaw Fence – Step-by-Step
Now let’s go through the full process of building a resaw fence from start to finish:
Step 1 – Cut the Fence Blank
Good stable materials for the fence include MDF, plywood, or hardwood boards. Cut a rectangular blank that is 3-4″ wide x 24″ tall minimum. I recommend using 3/4″ thick material or stacking thinner boards.
Step 2 – Mark Fence Bar Slot
The fence bar is what mounts the fence onto the bandsaw table. Mark a centered slot along the length of the fence blank that matches your fence bar size. A standard fence bar is 3/8″ x 3/4″.
Step 3 – Cut & Mount the Fence Bar
Use a straight bit in a router table to cut the fence bar slot. Clamp the fence bar in place and predrill screw holes to mount it from the backside.
Step 4 – Attach a Faceplate
For smoothness and rigidity, attach a hardboard or UHMW polyethylene faceplate to the front of the fence with glue and screws. This reduces friction when sliding workpieces.
Step 5 – Add Adjustment Mechanism
There are a few options for adding adjustment capability:
- Threaded rod with knobs – Simple and effective
- Rack and pinion – Precise adjustment
- Cam lever – Quick locking at presets
Mount the mechanism so the fence face can be moved precisely parallel to the bandsaw table.
Step 6 – Attach Support Rollers/Bearings
Adhere rollers or ball bearings along the fence face to support the workpiece during resawing. Some options:
- Hard nylon wheels
- Sealed roller bearings
- UHMW polyethylene strips
Space them 2-3″ apart along the length of the fence.
Step 7 – Add Dust Collection (Optional)
Cut slots or holes in the fence blank before assembly to integrate dust collection ports from a shop vacuum hose. Or attach flexible vacuum hose along the back side.
Step 8 – Final Sanding & Finish
Sand all edges and surfaces smooth. An oil finish protects the fence from glue and resin. Waxing the faceplate periodically helps boards slide smoothly.
Tips for Using Your Resaw Fence
Here are some tips to use when putting your new resaw fence to work:
- Check for parallel – Adjust the fence so it’s parallel to the bandsaw table
- Use thinner blades – 1/4″ to 3/8″ blades work best for most resawing
- Cut relief kerfs – Use multiple blades or saw kerfs when resawing wide boards to avoid pinching
- Take light passes – Don’t try to cut the full thickness in one pass
- Keep proper blade tension – The blade should have just a slight deflection or vibration in the cut
- Use a coolant – Either mist or brush on a coolant/lubricant for smooth cutting action
Follow those tips and your new resaw fence will deliver accurate, smooth-cutting performance for all your bandsaw resawing tasks!
Conclusion
Adding an adjustable resaw fence is one of the best upgrades you can make to a bandsaw. With a properly designed and built fence, you’ll achieve excellent precision when cutting veneers, reducing stock thickness, or resawing lumber into thinner boards.
The key steps are building a tall, rigid, and parallel fence; integrating smooth adjustment and workpiece support features; and taking light passes with the proper blade and coolant.
Resawing opens up many possibilities that would otherwise not be feasible without a bandsaw. So take the time to construct a quality fence and you’ll get years of use resawing wood on your bandsaw!