Ellis Band Saw: Capacity, Controls, and Ownership Notes

You run a small metal fabrication shop and you need a saw that can cut angles accurately. A horizontal saw that requires repositioning the material for every angle is too slow. You have heard that Ellis makes a miter band saw that swivels the head instead of the material. You want to know if it is worth the investment.

Ellis Band Saw Company makes a line of metal-cutting band saws designed for small to medium fabrication shops. Their saws are known for miter cutting capability, durability, and simple operation. They are not the cheapest saws on the market, but they are built to last.

Ellis Band Saw Model Lineup

Ellis 1000 Series

The entry-level Ellis saw. A horizontal band saw with manual feed and a swivel head for miter cutting.

• Cut capacity: 5-1/2 inches round, 7 x 5-1/2 inches rectangular
• Miter range: 0 to 60 degrees right, 0 to 45 degrees left
• Blade length: 80 inches
• Blade width: 3/4 to 1 inch
• Motor: 1 HP, 110V or 220V
• Weight: Approximately 350 pounds
• Features: Hydraulic downfeed, coolant system, quick-locking vise

Ellis 1600 Series

The most popular Ellis saw. A larger horizontal miter saw with more capacity and heavier construction.

• Cut capacity: 8-1/2 inches round, 9 x 8 inches rectangular
• Miter range: 0 to 60 degrees right, 0 to 45 degrees left
• Blade length: 93-1/2 inches (some models use 91-1/2 inches)
• Blade width: 3/4 to 1 inch
• Motor: 1-1/2 HP, 110V or 220V
• Weight: Approximately 500 pounds
• Features: Hydraulic downfeed, coolant system, dual vise (clamps both sides of cut)

Ellis 1800 Series

A larger version of the 1600 with more cut capacity.

• Cut capacity: 10-1/2 inches round, 12 x 10 inches rectangular
• Miter range: 0 to 60 degrees right
• Blade length: 100 inches (some models use 105 inches)
• Blade width: 1 to 1-1/4 inches
• Motor: 2 HP, 220V
• Weight: Approximately 700 pounds
• Features: Hydraulic downfeed, coolant system, power feed option

Ellis 3000 Series

The largest Ellis saw. Designed for heavy fabrication and production cutting.

• Cut capacity: 14 inches round, 16 x 14 inches rectangular
• Miter range: 0 to 45 degrees right
• Blade length: 124 inches
• Blade width: 1 to 1-1/4 inches
• Motor: 3 HP, 220V or 440V
• Weight: Approximately 1200 pounds
• Features: Hydraulic downfeed, coolant system, automatic shut-off

Miter Cutting: The Ellis Advantage

The key feature of Ellis saws is the swivel head. Instead of rotating the material in the vise to cut an angle, you rotate the saw head while the material stays in the vise. This has several advantages.

Speed: Changing the cut angle takes seconds. Loosen the head lock, rotate to the desired angle, and lock. No need to reposition the material.

Accuracy: The angle indicator on the head is more accurate than the angle scale on most vises. The head locks at common angles (0, 15, 30, 45 degrees) with positive stops.

Material support: Because the material does not move, you can support long pieces on a roller stand without repositioning the support for each angle change.

Dual-direction miter: Ellis saws swivel both left and right (on most models), giving you more flexibility in how you position the saw in your shop.

Blade Selection for Ellis Saws

Ellis saws use wider blades than portable saws. The wider blade tracks straighter and handles the longer cut lengths typical of horizontal saw work.

Blade material: Bi-metal M42 is the standard. For production cutting of stainless or tool steel, consider carbide-tipped blades.

TPI for thick stock (2+ inches): 6/10 or 8/12 variable pitch. Coarse teeth bite deep and clear chips fast.

TPI for medium stock (1/2 to 2 inches): 10/14 variable pitch. Good all-around choice for most work.

TPI for thin stock (under 1/2 inch): 14/18 variable pitch. Fine teeth prevent grabbing in thin material.

Blade brands: LENOX, MK Morse, and Starrett all make blades in the lengths used by Ellis saws. Ellis sells their own branded blades, but they are manufactured by one of these companies.

Setup and Operation

Install the blade. Open the wheel covers, loop the blade around both wheels with the teeth pointing toward the cut direction, close the covers, and tension the blade. Ellis saws have a blade tension indicator that shows when the blade is properly tensioned.

Set the miter angle. Loosen the head lock lever, rotate the head to the desired angle using the angle scale, and lock the lever. The positive stops at common angles ensure accuracy.

Set the feed rate. The hydraulic downfeed controls how fast the saw head descends. Adjust the hydraulic valve to control the descent rate. Start slow and increase until you see a continuous chip curl.

Use coolant. Ellis saws come with a coolant system. Fill the coolant tank with a good quality cutting fluid. The coolant pump floods the blade with fluid during cutting, extending blade life by 30 to 50 percent.

Clamp the material. The quick-locking vise holds the material during cutting. For angled cuts, the material stays in the vise and the head rotates. Make sure the vise is tight before starting the cut.

Common Ownership Issues

Blade tracking: If the blade drifts to one side, check the wheel alignment and tire condition. Ellis saws have adjustable wheel tracking. Clean the tires regularly to prevent chip buildup.

Hydraulic downfeed: The hydraulic cylinder can develop leaks after years of use. If the head descends too fast or erratically, the hydraulic seal may be worn. Ellis sells replacement hydraulic cylinders.

Coolant pump: The coolant pump can clog with chips and debris. Clean the pump filter regularly. If the pump stops working, check for a clogged intake or a worn impeller.

Vise wear: The vise jaws can wear after years of use. If the vise does not hold material tightly, replace the jaw plates. Ellis sells replacement jaws.

Motor: The motor on Ellis saws is a standard NEMA frame motor. Bearings are replaceable. If the motor hums but does not start, the start capacitor may be bad.

Parts and Support

Ellis Band Saw Company provides good parts support. They maintain a parts list for each model and sell directly from their factory in Wisconsin. Common wear parts (blades, vise jaws, hydraulic cylinders, coolant pumps) are available. The saws are designed to be serviceable by the owner with basic tools.

FAQ

What makes Ellis band saws different from other horizontal saws?

The swivel head. Instead of rotating the material for angled cuts, you rotate the saw head. This is faster, more accurate, and easier for long material.

What blade does an Ellis 1600 use?

A 93-1/2 inch blade (some models use 91-1/2 inches) in 3/4 to 1 inch width. Bi-metal M42 is the standard material.

How much does an Ellis band saw cost?

The 1000 series costs about 2,500 to 3,500 dollars. The 1600 series costs about 3,500 to 5,000 dollars. The 1800 costs about 5,000 to 7,000 dollars. The 3000 costs about 8,000 to 12,000 dollars.

Can I cut stainless steel with an Ellis saw?

Yes. Use a bi-metal blade with 10/14 TPI, slow blade speed, and flood coolant. For production stainless cutting, consider a carbide-tipped blade.

Where are Ellis band saws made?

Ellis Band Saw Company is located in Wisconsin, USA. The saws are assembled in the USA, though some components may be imported.

How do I set the miter angle on an Ellis saw?

Loosen the head lock lever, rotate the head to the desired angle using the angle scale, and lock the lever. Positive stops at common angles (0, 15, 30, 45 degrees) ensure accuracy.

References

• Ellis Band Saw Company. “Product Line Overview.” EllisSaw.com.
• Ellis Band Saw Company. “Model 1600 Owner’s Manual.”
• LENOX Tools. “Horizontal Band Saw Blade Selection Guide.” LENOX Industrial Division.
• MK Morse. “Production Band Saw Blade Guide.” MK Morse Company.
• Practical Machinist. “Ellis Band Saw Owner Reviews.” practicalmachinist.com.