Bandsaw Blade Size Guide for Sawmills
Sawmill Videos by Cooks Saw MFG.
Video Transcript Summary
Video Run Time 29:08
Choosing the Right Bandsaw Blade Size for Your Sawmill
Not sure what bandsaw blade size is right for your sawmill setup? Whether you're running a hobby mill with a 20 HP motor or a high-output production mill with 60+ HP, choosing the correct blade size can make or break your cut quality, blade life, and overall efficiency.
In this video, Robert and Tim from Cooks Saw break down blade widths, thicknesses, and tooth spacing to help you match the right blade to your sawmill's horsepower, wheel diameter, and production goals.
Scroll through the key points below to learn how blade size impacts cutting speed, longevity, and sawmill performance.
Best Bandsaw Blade Size for Hobby Sawmills (20–25 HP)
If you're running a hobby mill in the 20–25 HP range—like the MP-32—a 1-1/4” bandsaw blade is your best match. It delivers maximum cutting power for smaller motors without bogging them down or adding unnecessary cost.
Robert and Tim explain that while it’s tempting to upgrade to a wider blade, it rarely improves cut quality on small sawmills. In fact, if your mill isn’t aligned or your blade isn’t sharp, a wider blade might make things worse. Proper blade set, sharpness, and alignment will give you better results than going wider.
Pro Tip: A properly set and sharpened 1-1/4” blade will saw straight and efficiently—no horsepower wasted.
When to Move Up to 1-1/2” and 2” Bandsaw Blades
Once you move beyond 30 HP, your sawmill has enough power to handle wider blades—and that's when upgrading to a 1-1/2” or 2” bandsaw blade starts to make sense.
Robert and Tim explain that sawmills with 35–50 HP motors benefit from 1-1/2” blades, especially when paired with 26" or larger band wheels. If you're running 60+ HP and sawing thousands of board feet per day, a 2” blade can help you cut faster and with more beam strength.
But wider blades aren't plug-and-play. They require precise alignment, sharper tension control, and more attention to setup. Without that, even a 2” blade won’t perform as expected.
Bottom line: Match your blade width to your horsepower and production goals—not just what “seems better.”
Explore high-performance blades for heavy-duty sawmills AC3651 & AC3649
Why Wider Bandsaw Blades Don’t Always Improve Cut Quality
It’s a common sawmill myth—if your blade isn’t cutting straight, just upgrade to a wider one. But as Robert and Tim point out, wider bandsaw blade sizes won’t fix wavy cuts if your mill isn’t aligned correctly.
Bigger blades introduce more complexity: they require tighter tolerances, more precise band wheel alignment, and better overall mill setup. Without that foundation, a 1-1/2” or 2” blade may actually cause more problems than it solves.
Fix first, then upgrade: Blade width won’t save a misaligned mill. Always tune alignment, blade set, and sharpness before blaming the blade size.
️ Improve blade accuracy with Cooks’ sharpener and dual tooth setter combo
Tooth Configuration: What Actually Cuts Better
Tooth design matters just as much as blade size. At Cooks, our blades use a proven left-right-center tooth pattern—often called “spring set” or “drag tooth.” This setup evenly distributes the cutting load and keeps your blade tracking straighter through the cut.
Some blades on the market feature a full-width single tooth, but that design creates excessive pressure on the gullet and causes premature blade failure. It might seem aggressive, but it leads to cracks, overheating, and rougher cuts.
Better design = better cuts: The alternating set configuration allows for smoother feed, cleaner kerfs, and longer-lasting performance.
Maximize Bandsaw Blade Life with Proper Setup
Want your bandsaw blades to last longer? Blade size is just one part of the equation. To truly extend blade life, it comes down to setup, maintenance, and how hard you're pushing the blade through the cut.
According to Robert and Tim, thinner blades—like 1-1/4” or 1-1/2” with .042 thickness—generally last longer due to greater flex. But even the best blade won’t survive poor tension, aggressive feed rates, or dull teeth.
Key blade life tips:
- Back off tension just a bit to reduce fatigue
- Sharpen more often to reduce stress on the metal
- Adjust feed rate based on wood species and condition
Keep blades sharper, longer—check out our sharpener and setter combo
Blade Recommendations for Pallet Mills
If you're sawing for pallet production, your needs are different—and your blade size should reflect that. Robert and Tim recommend 1” to 1-1/4” blades for most pallet mills, especially when cutting narrow material like 4" to 6" wide stock.
Why? These narrower blades are easier to maintain, more affordable, and work great on 20" to 26" band wheels. They’re quick to sharpen and deliver the speed and efficiency pallet mills need.
Pallet resaws run lean: Keep your blade choice simple and effective with a lighter blade that’s built for volume.
Tooth Spacing: 7/8” vs. 1”—What’s the Difference?
Tooth spacing plays a huge role in how efficiently your bandsaw blade cuts and clears sawdust. In this clip, Robert and Tim break down when to use 7/8” spacing versus 1”.
7/8” spacing gives you finer control and works best when cutting hardwoods or frozen logs. It’s easier on the mill and handles dense material with precision. 1” spacing feeds faster and handles larger sawdust particles better, making it ideal for softwoods and high-production runs.
Quick tip: Powdered sawdust causes heat and friction. Larger chip removal with 1” tooth spacing keeps your blade cooler and cutting faster.
When to Run a 2” Bandsaw Blade
If you’re running a high-production sawmill with 60–70+ HP and a full crew, a 2” bandsaw blade can help you saw faster and more aggressively. These wide blades offer excellent beam strength and feed rate performance—but only if your mill is precisely aligned and you’re ready to stay on top of sharpening.
Robert and Tim caution that 2” blades aren’t ideal for beginners. They’re unforgiving, and improper tension or poor alignment will cause premature blade failure.
Start with 1-1/2” blades first: Once you’ve mastered blade tensioning, feed speed, and guide alignment, then step up to a 2” blade for peak output.
FAQs: Choosing the Right Bandsaw Blade Size
Solution: Check blade sharpness, set, and mill alignment before switching blade size.
Solution: Upgrade when you’ve got 35+ HP and 26”+ wheels—and only if alignment is dialed in.
Solution: Sharpen often, use proper tooth set, and lower tension to reduce fatigue.
Solution: Use 1” to 1-1/4” blades for pallet cutting on 20"–26" wheels. They’re efficient and easy to maintain.
Solution: 7/8” for hardwoods and control; 1” for softwoods and faster feed rate.
Solution: With proper use, a blade can last 15–20 sharpenings. Don’t push dull blades.
Solution: Sharpen every 1,500–2,000 board feet or when cut quality drops.
Solution: Use just enough to saw straight. Higher tension = faster cuts, but less longevity.
Solution: Use quality blades, avoid over-tensioning, and keep teeth sharp.
Solution: Always match blade width and length to HP, wheel diameter, and cut application.
Still unsure what blade size you need?
Call us at 1-800-473-4804 or email sales@cookssaw.com and we’ll help you pick the perfect bandsaw blade for your sawmill.
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