How to Build a Delta Milwaukee Band Saw Fence: A Stable Build for Accurate, Repeatable Cuts

You have a Delta Milwaukee 14-inch band saw that you restored. New tires, new bearings, new blade guides. The saw runs great. But the fence is missing. The original Delta fence was adequate at best, and finding a used one in good condition is difficult. You decide to build your own.

A good band saw fence needs to do three things: stay parallel to the blade, lock securely without shifting, and be adjustable for drift. The stock Delta fence does the first two adequately but cannot adjust for drift. A custom fence can do all three and cost less than a commercial replacement.

Why the Stock Delta Fence Falls Short

The original Delta 14-inch fence is a simple aluminum extrusion that clamps to a round bar mounted on the table. It works for basic ripping but has several limitations.

No drift adjustment. Band saw blades drift. Even a well-tuned saw with a sharp blade will cut at a slight angle to the fence. The stock fence is fixed at 90 degrees to the table and cannot be adjusted to compensate for drift.

Flex. The aluminum fence is thin and flexes under pressure. If you push the workpiece against the fence, the fence can deflect, producing an angled cut.

Inadequate locking. The stock clamp can slip during a cut, especially in hardwood. A slipping fence ruins the cut and can be dangerous.

No resaw height. The stock fence is low. For resawing, you need a tall fence that supports the full height of the board. The stock fence is only about 1-1/2 inches tall.

Design Options for a Custom Fence

Option 1: Simple Wood Fence

The simplest approach. A piece of hardwood (oak or maple) bolted to the existing fence rail. Cost: 5 dollars. Time: 1 hour.

Pros: Cheap, easy to build, can be made any height for resawing. Cons: Not adjustable for drift, wood can warp, not as rigid as metal.

Option 2: Drift-Adjustable Fence

A fence mounted on a pivot that allows angle adjustment for drift. Made from aluminum angle stock and hardware. Cost: 30 to 50 dollars. Time: 3 to 4 hours.

Pros: Adjustable for drift, rigid, repeatable. Cons: Requires more fabrication, needs a pivot mechanism.

Option 3: Kreg or Carter Fence (Commercial)

If you do not want to build, buy a commercial fence. Kreg makes a precision band saw fence for about 130 dollars. Carter makes one for about 200 dollars. Both are drift-adjustable and well-built.

Pros: Precision, easy to install, well-designed. Cons: Cost.

Building a Drift-Adjustable Fence (Option 2)

Here is how to build a drift-adjustable fence for the Delta Milwaukee 14-inch band saw.

Materials

• 1 piece aluminum angle, 3/4 x 3/4 inch, 24 inches long (the fence face)
• 1 piece aluminum flat bar, 1/4 x 1-1/2 inch, 6 inches long (the mounting block)
• 2 pieces 1/4-20 threaded inserts
• 2 pieces 1/4-20 x 1 inch knob-head bolts (for locking)
• 1 piece 10-32 x 3/4 inch bolt (for the pivot)
• 1 piece 10-32 nyloc nut
• 1 piece hardwood, 3/4 x 3 x 24 inches (the resaw fence extension)

Tools

• Drill with 1/4 inch and 10/32 inch bits
• Tap wrench and 1/4-20 tap
• Hacksaw or metal-cutting saw
• Files for deburring
• Combination square

Steps

1. Make the mounting block. Cut the aluminum flat bar to 6 inches. Drill two 1/4 inch holes through the bar, spaced to match the existing fence rail holes on your Delta table. Tap the holes for 1/4-20 threaded inserts. These inserts let you bolt the mounting block to the existing fence rail.

2. Make the fence face. Cut the aluminum angle to 24 inches. The angle forms an L-shape that serves as the fence. One leg is vertical (the fence face), the other is horizontal (the base that mounts to the pivot).

3. Create the pivot. Drill a 10/32 hole through the mounting block and the horizontal leg of the fence face. The hole should be near one end of the mounting block. Install the 10-32 bolt through both pieces with a nyloc nut. This is the pivot point. The fence can now rotate around this bolt.

4. Create the angle lock. Drill a 1/4 inch hole through the mounting block and the horizontal leg of the fence face near the other end of the mounting block. Tap for 1/4-20 threaded inserts. Install a 1/4-20 knob-head bolt through the insert. When you tighten this bolt, it locks the fence angle.

5. Make the resaw extension. Cut the hardwood to 3/4 x 3 x 24 inches. Bolt it to the vertical leg of the aluminum angle using two machine screws. The hardwood extension gives you a 3-inch tall fence for resawing.

6. Install the fence. Bolt the mounting block to the existing fence rail on your Delta table. Align the fence parallel to the blade using a combination square. Tighten the mounting bolts.

7. Adjust for drift. Make a test cut in a piece of scrap. If the cut drifts away from the fence, loosen the angle lock bolt, rotate the fence slightly to match the drift angle, and retighten. Make another test cut. Repeat until the cut follows the fence.

Using the Fence for Resawing

For resawing, you need the tall hardwood extension. Here is how to set up for a resaw cut.

1. Install the widest blade you have (1/2 to 3/4 inch, 3 TPI hook tooth bi-metal).
2. Tension the blade properly (about 15,000 PSI for a 1/2 inch blade).
3. Set the fence for drift using the pivot adjustment.
4. Mark the board on both edges where you want the cut.
5. Feed the board into the blade with light pressure against the fence.
6. Keep the board flat on the table and pressed against the fence.
7. Feed slowly. Let the blade do the work. Do not force the cut.
8. If the cut wanders, adjust the fence angle slightly and try again.

Tips for Accuracy

Mark the drift angle. Once you find the drift angle for a specific blade, mark it on the fence mounting block with a pencil. This lets you quickly reset the fence when you change blades.

Check the fence alignment regularly. Vibration can loosen the mounting bolts. Check the fence alignment with a combination square before each resawing session.

Use a stabilizer block. For tall resawing, a block of wood clamped to the table behind the fence helps support the board and prevent it from tipping.

Wax the table. A coat of paste wax on the table reduces friction and makes feeding easier. This is especially important for resawing, where the board is in contact with the table for a long time.

FAQ

Why do I need a drift-adjustable fence?

Band saw blades drift. Even a well-tuned saw cuts at a slight angle to the fence. A drift-adjustable fence lets you match the fence angle to the blade’s drift, producing straight cuts.

Can I use the stock Delta fence for resawing?

The stock fence is only about 1-1/2 inches tall. For resawing 6-inch boards, you need a taller fence. You can clamp a board to the stock fence as a temporary extension, but a purpose-built tall fence is better.

How much does it cost to build a custom fence?

A drift-adjustable fence made from aluminum angle and hardware costs about 30 to 50 dollars. A commercial Kreg fence costs about 130 dollars.

What is the best blade for resawing with a custom fence?

A 1/2 to 3/4 inch wide, 3 TPI hook tooth bi-metal blade. The wide blade tracks straight, the coarse teeth clear chips fast, and the bi-metal edge survives the heat of deep cuts.

How do I find the drift angle?

Draw a straight line on a piece of scrap wood. Cut along the line freehand, following the blade’s natural path. After a few inches, stop the saw and measure the angle between the cut line and the straight line. That is your drift angle.

Can I use this fence design on other band saws?

Yes. The design is adaptable to any 14-inch band saw with a fence rail. Adjust the mounting block dimensions to match your saw’s fence rail spacing.

References

• Mark Duginske. “The Band Saw Book.” Taunton Press.
• Lonnie Bird. “Band Saw Handbook.” Sterling Publishing.
• Carter Products. “Band Saw Fence Design Guide.” Carter Products.
• Kreg Tool. “Precision Band Saw Fence Installation Guide.” Kreg Tool Company.
• Fine Woodworking. “Building a Better Band Saw Fence.” Taunton Press.