Ellis Band Saw 1600: Specifications, Blade Size, and Parts Support
You are considering buying an Ellis 1600 band saw for your fabrication shop. You cut a lot of angle iron, tubing, and bar stock at various angles, and you need a saw that can miter cut without repositioning the material. You want to know the specifications, blade requirements, and what to expect in terms of maintenance and parts support before you spend the money.
The Ellis 1600 is the most popular model in the Ellis band saw lineup. It is a horizontal miter band saw designed for small to medium fabrication shops. The swivel head allows miter cutting from 0 to 60 degrees right and 0 to 45 degrees left without moving the material. This makes it significantly faster than conventional horizontal saws for angled cuts.
Specifications
| Specification | Value |
|---|---|
| Cut capacity (round) | 8-1/2 inches |
| Cut capacity (rectangular) | 9 x 8 inches |
| Miter range | 0 to 60 degrees right, 0 to 45 degrees left |
| Blade length | 93-1/2 inches (some models 91-1/2 inches) |
| Blade width | 3/4 to 1 inch |
| Blade speed | Approximately 200 to 300 SFPM |
| Motor | 1-1/2 HP, 110V or 220V |
| Weight | Approximately 500 pounds |
| Coolant system | Yes, with pump and tank |
| Hydraulic downfeed | Yes, adjustable |
| Vise | Quick-locking, dual clamp |
Miter Cutting
The key feature of the Ellis 1600 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 stationary.
How it works: Loosen the head lock lever, rotate the head to the desired angle using the angle scale, and lock the lever. The head has positive stops at 0, 15, 30, and 45 degrees for quick, accurate setup. For angles between the stops, use the angle scale and lock the head manually.
Advantages over conventional horizontal saws:
- Speed: Changing the cut angle takes seconds instead of minutes
- Accuracy: The head angle indicator is more precise than vise angle scales
- Material support: Long pieces stay on roller stands without repositioning
- Dual-direction: The head swivels both left and right for shop layout flexibility
Blade Selection
The Ellis 1600 uses a 93-1/2 inch blade (some models use 91-1/2 inches). Check your saw’s manual for the exact length. The blade width is 3/4 to 1 inch, wider than portable band saw blades.
Blade material:
- Bi-metal M42: The standard for most work. Handles carbon steel, stainless steel, aluminum, and cast iron.
- Carbide-tipped: For production cutting of stainless or tool steel. Lasts 5 to 10 times longer than bi-metal but costs 3 to 5 times more.
TPI selection:
- 6/10 variable pitch: Thick solid bar (2+ inches). Coarse teeth bite deep and clear chips fast.
- 10/14 variable pitch: Medium stock (1/2 to 2 inches). The best all-around choice for most work.
- 14/18 variable pitch: Thin stock (under 1/2 inch). Fine teeth prevent grabbing.
Blade brands: LENOX, MK Morse, and Starrett all make blades in 93-1/2 inch lengths. Ellis sells their own branded blades, but they are manufactured by one of these companies. LENOX and MK Morse blades typically outlast the Ellis branded blades by 20 to 30 percent.
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. The Ellis 1600 has 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, and lock the lever. Check the angle with a protractor for critical cuts.
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. Too fast and the blade will dig in and stall. Too slow and the blade will rub and dull.
Use coolant. 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. Check the coolant level regularly and top off as needed.
Clamp the material. The dual vise clamps both sides of the cut, preventing the material from shifting during cutting. For angled cuts, the material stays in the vise and the head rotates. Make sure both vise jaws are tight before starting the cut.
Common Repairs
Hydraulic Downfeed Leaks
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. The repair takes about 30 minutes with basic tools.
Coolant Pump Clogging
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. Replacement pumps are available from Ellis.
Vise Jaw 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 that bolt onto the existing vise.
Blade Tracking Issues
If the blade drifts to one side, check the wheel alignment and tire condition. The Ellis 1600 has adjustable wheel tracking. Clean the tires regularly to prevent chip buildup. If the tires are cracked or have flat spots, replace them with urethane tires.
Motor Problems
The motor is a standard NEMA frame motor. Bearings are replaceable. If the motor hums but does not start, the start capacitor may be bad. If the motor runs but has no power, the bearings may be worn. Replacement motors are available from Ellis or any industrial motor supplier.
Parts Support
Ellis Band Saw Company provides good parts support. They maintain a parts list for the 1600 and sell directly from their factory in Wisconsin.
Common wear parts:
- Blades (93-1/2 inch, 3/4 to 1 inch wide)
- Vise jaw plates
- Hydraulic cylinders
- Coolant pumps
- Drive belts
- Wheel tires
- Blade guide bearings
Parts availability: Common wear parts are in stock and ship quickly. Less common parts may take a few days. The saws are designed to be serviceable by the owner with basic tools.
FAQ
What blade does the 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 the Ellis 1600 cost?
New, the 1600 series costs about 3,500 to 5,000 dollars depending on configuration and options.
Can the Ellis 1600 cut stainless steel?
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.
What is the cut capacity of the Ellis 1600?
8-1/2 inches round and 9 x 8 inches rectangular. This handles most common structural steel, pipe, and bar stock.
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 the Ellis 1600?
Loosen the head lock lever, rotate the head to the desired angle using the angle scale, and lock the lever. Positive stops at 0, 15, 30, and 45 degrees ensure accuracy.
References
- Ellis Band Saw Company. “Model 1600 Owner’s Manual.” EllisSaw.com.
- Ellis Band Saw Company. “Parts List for Model 1600.” Ellis Band Saw Company.
- LENOX Tools. “Horizontal Band Saw Blade Selection Guide.” LENOX Industrial Division.
- MK Morse. “Production Band Saw Blade Guide.” MK Morse Company.
- Practical Machinist. “Ellis 1600 Owner Reviews.” practicalmachinist.com.
