About Falberg Saw Company
Falberg Saw Co. started back in 1999 when I was commissioned to reproduce an Herbert Bayer sculpture called "Totem" which consisted of two really snaky rip cuts through a large timber.
For the CUTS You Just CAN'T Make with ANY other SAW
I still don't know how the original "Totem" was cut, but, at the time, I had to believe the only evidence available in the dusty archives: a grainy black and white photo of two guys smiling at the cameras in front of a mammoth industrial behemoth band saw that looked like a WWII-era factory. There was nothing resembling a Totem in the picture, nor any sign of wood anywhere, but I had to assume these two factory workers managed to wrestle a 12"x12"x12' long timber perfectly through a long series of linked semi-circles running precisely down the center of said timber; clamp the halves together; and do it again, perfectly, down the adjacent side to expose the reciprocal radii of the four resulting pieces.
If they cut it from a single timber, it was an amazing feat of coordination. If they used four smaller timbers, it was still an amazing feat of coordination, but an even greater job of lay-out and design. Not having a factory or a skilled partner, I was forced to improvise. I found this Delta 16" motorized band saw and commenced to chop off all unnecessary cast iron, leaving only the motor and blade transport system.
It worked, and you could save a lot of money doing the same. But I gotta warn you; it was extremely heavy; and "klunky" doesn't begin to describe how miserable it was to use.
The original Delta got dropped on my garage floor and its frame was irreparably cracked, so I build a lighter version of the Delta with a donut-shaped, closed throat, homemade aluminum frame using the motor, wheels, and blade guides from the old Delta. It worked beautifully and, despite its closed throat, is still in use today. View our first brochure.
It took three more years to perfect a C-shaped frame with 18" of width and sufficient tension to outrun any chainsaw on the open timber.
But, rough as they were, local timber framers started buying them and building custom homes with the "Rocky Mountain" look.
Every saw since then has been an improvement; and now, 15 years later, having doubled the throat area, eliminated all vibration (machined 6061 wheels) and blade flappage (frictionless tensioning), it's hard to imagine what else I can do. The lever-action tensioner I introduced in 2003 went over pretty well.
The frictionless tensioner will too.
I'm starting a custom saw project to build a metal-cutting three wheeler with higher tension, a heavier frame, and direct drive to be hung from the ceiling by a robotic arm.
This could very well lead to another major breakthrough in band saw leanness and meanness. Once again - you'll see it here first!
My sons, pictured below, found better jobs (with weekly pay checks), but I hope they'll carry on when I retire. They're the only ones who know how.
Bebop Rafter Tail
How to cut a fancy ogee rafter tail the EASY way
Click on image to the right to watch video