Where I work; long established, small, family run. That can mean the depth of experience is limited. Most common phrase, "always did it this way."
Yikes.
Hard to find a manual machine more efficient profiling work pieces than a bandsaw. I say, IMNSHO there isn't.
But free handing straight cuts requires bluing and scribing a layout, that many people can get .020 positive [.50mm] said layout.
I have order for 16 swing bolts 2" diameter, 18" long. I've made these twice before. They've freehanded them for decades. My second piece, umm no thanks. I'll clamp a bar of CRS to table. OK, but tedious setup. First op center drilled each end carefully, only way to get decent 2" threads in 2" thick stock, supported by centers, dog driven.
All remnant and drop material. Aluminum
rescued from waterjetted plate of unrelated levers.
Cold rolled rail and face.
Sliding along front rail, position secures very
well via knob clamp screws. This view has cap screws in
key slots and strip washer. That allows easy removal, whereas
blade obstructs each side.
Parallel sides make setups far
easier to machine. Ultimately will saw big radius off to
natural, space saving angle. Interior wedges
sawn by drilling, passing band blade through
and rewelding. Done, just recut blade.
Commercial hardware;
cap & set screws, all thread, hand knobs, jam nuts.
Clamps are slightly less spread than set screws.
Set screws, fine threaded, adjust squareness.
No plans. No plans needed other than tape measure.
Motivation,
Factory version just under $1000.00 USD.
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