This project was built and designed by Izzy Swan. It demonstrates how a simple jig can transform a standard bandsaw into a reliable alternative for flattening lumber, helping woodworkers avoid the cost, space demands, and dust collection challenges of a traditional jointer.
Izzy’s method is particularly useful for small-shop woodworkers or those who don’t work with rough lumber often. With just a bit of planning and tuning, your existing bandsaw can take on tasks normally reserved for much bulkier tools.
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Why a Jointer Isn’t Always Necessary
Jointers are highly effective for flattening boards and preparing rough lumber, but they also come with drawbacks. They’re large, expensive, and produce a lot of dust, requiring a strong collection setup to run safely and cleanly.
For woodworkers who mostly use S4S lumber, a jointer might sit idle for long periods. That makes it hard to justify the investment, especially when there’s a creative workaround that uses a tool many already own—the bandsaw.
Using the Bandsaw Differently
Bandsaws are often associated with cutting curves or resawing, but their potential goes far beyond that. When paired with a properly built jig, they can flatten boards with surprising accuracy.
The key to this technique is stability—both from the jig and from the saw itself. With the right jig, proper clamping, and a well-tuned machine, it’s entirely possible to create flat, straight cuts on boards that otherwise would require jointing.
Building the Flattening Jig
The jig starts with a solid base. It needs to be wide and long enough to support the boards you plan to work with and stiff enough to resist flexing during clamping and cutting.
On top of the base, Izzy adds a clamp system to keep boards secure. This system includes a sliding clamp face and a carriage bolt that allows for easy adjustment depending on the board thickness. When tightened, the board stays put for clean, consistent passes through the blade.
Adding anti-slip material to both the base and the clamp surface can prevent movement during cutting. This helps maintain a consistent feed rate and prevents uneven results.
Getting Your Bandsaw Ready
Before using the jig, it’s critical that your bandsaw is properly tuned. That means checking blade tension, tracking, and ensuring the guides are positioned correctly.
A misaligned bandsaw will produce wavy or uneven cuts, no matter how well the jig is built. Izzy encourages taking the time to set up your machine for optimal performance—especially if you plan to rely on it for this type of work regularly.
Using the Jig in Practice
Once the jig is complete and your bandsaw is tuned, flattening lumber becomes a repeatable process. Start by clamping your board into the jig and feeding it slowly and steadily through the saw.
A consistent feed rate and proper blade selection are key here. Izzy uses a resaw blade with fewer teeth per inch, which reduces resistance and keeps the blade from wandering during the cut.
After the first face is cut, the board can be flipped and passed through again, resulting in two flat and parallel surfaces—just like a jointer would provide, but without the same footprint or cost.
Important Tips for Best Results
- Use a resaw blade: A low TPI blade helps reduce resistance and deflection, especially on thicker stock.
- Apply even pressure: Keep the feed rate consistent from start to finish to avoid blade drift.
- Check for square: After the cut, verify that the surface is flat and square. Minor sanding may be needed, but it’s often minimal.
- Maintain the jig and bandsaw: Keep blades sharp, surfaces clean, and check for any signs of wear over time.
An Efficient Alternative for Small Shops
For many woodworkers, this bandsaw jig setup is a game-changer. It frees up space, avoids the cost of another large tool, and makes better use of what’s already in the shop. Plus, it’s a clever way to extend the versatility of one of the most important tools in woodworking.
Izzy’s project is a good reminder that innovation doesn’t always mean adding tools—it can also mean making the most of what you’ve got. This jig is simple, effective, and easy to replicate.
Please support Izzy by visiting his website: https://www.izzyswan.com/.