Abstract:
A hand-held band saw for cutting a workpiece. The hand-held band saw includes a deck, first and second wheels coupled to the deck for receiving a continuous blade thereabout, a motor coupled to the deck for driving at least one of the first or second wheels, and a handle providing a grip for a user to hold the band saw. The band saw also includes a blade guard having a first portion adjacent the first wheel, a second portion adjacent the second wheel, and a third portion adjoining the first and second portions. A joint couples the first, second, and third portions to the deck for simultaneous movement of the first, second, and third portions with respect to the deck.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 14/193,457 filed Feb. 28, 2014, which is a divisional of U.S. patent application Ser. No. 13/153,090 filed Jun. 3, 2011, now U.S. Pat. No. 8,677,633, which claims priority to U.S. Provisional Patent Application No. 61/351,118 filed Jun. 3, 2010. The entire contents of all these applications are incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    The present invention relates to power tools, and more particularly to band saws. 
         [0003]    Band saws typically include a continuous band saw blade disposed about a pair of pulleys, or wheels, and driven by one of the pulleys, and a guard surrounding an outer circumference of the band saw blade. The guard covers the side of the band saw blade as it rotates about the wheels and protects the band saw blade from being disrupted and/or misaligned. The bottom of the band saw is open such that the band saw blade and pulleys are accessible for removal to facilitate band saw blade replacement. 
       SUMMARY OF THE INVENTION 
       [0004]    The invention provides, in one aspect, a method of manufacturing a band saw. The method includes providing a deck, coupling first and second wheels to the deck for receiving a continuous blade thereabout, coupling a motor to the deck for driving at least one of the first or second wheels, providing a handle for a user to hold the band saw, providing a blade guard having a first portion adjacent the first wheel and a second portion adjacent the second wheel, fixing the first and second portions to each other, and hingedly coupling the first and second portions to the deck for simultaneous movement with respect to the deck. 
         [0005]    In another aspect, the invention provides a hand-held band saw for cutting a workpiece. The hand-held band saw includes a deck, first and second wheels coupled to the deck for receiving a continuous blade thereabout, a motor coupled to the deck for driving at least one of the first or second wheels, and a handle providing a grip for a user to hold the band saw. The band saw also includes a blade guard having a first portion adjacent the first wheel, a second portion adjacent the second wheel, and a third portion adjoining the first and second portions. A joint couples the first, second, and third portions to the deck for simultaneous movement of the first, second, and third portions with respect to the deck. 
         [0006]    In yet another aspect, the invention provides a hand-held band saw for cutting a workpiece. The hand-held band saw includes a deck defining a front and a rear, the deck having an opening in the front defining a cut zone and a first deck portion generally located on a first side of the opening and a second deck portion generally located on a second side of the opening. The band saw also includes a first wheel supported by the first deck portion, a second wheel supported by the second deck portion, the first and second wheels for supporting a blade. The band saw also includes a motor operably coupled to the first wheel, a handle providing a grip for a user to hold the band saw, a blade guard configured to provide a barrier between the blade and an exterior of the band saw, and a joint between the blade guard and the deck such that the blade guard is movable with respect to the deck. The blade guard includes a first portion adjacent the first wheel, a second portion adjacent the second wheel, and a third portion adjoining the first and second portions such that the first, second, and third portions move as one piece with respect to the deck. 
         [0007]    Other features and aspects of the invention will become apparent by consideration of the following detailed description and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a top perspective view of a band saw according to one construction of the invention. 
           [0009]      FIG. 2  is a front view of the band saw shown in  FIG. 1 . 
           [0010]      FIG. 3  is a top view of the band saw shown in  FIG. 1 . 
           [0011]      FIG. 4  is a left side view of a band saw shown in  FIG. 1 . 
           [0012]      FIG. 5  is a bottom perspective view of a portion of the band saw shown in  FIG. 1 . 
           [0013]      FIG. 6  is a cross section of a portion of the band saw of  FIG. 3  taken along line  6 - 6 . 
           [0014]      FIG. 7  is a bottom perspective view of the band saw of  FIG. 1  shown in an open position. 
           [0015]      FIG. 8  is a rear view of the band saw shown in  FIG. 1 . 
           [0016]      FIG. 9  is an exploded view of a portion of the band saw shown in  FIG. 1 . 
           [0017]      FIG. 10  is an exploded view of a portion of the band saw shown in  FIG. 1 . 
           [0018]      FIG. 11  is an exploded view of a portion of the band saw shown in  FIG. 1 . 
           [0019]      FIG. 12  is a bottom view of the band saw shown in  FIG. 1 . 
           [0020]      FIG. 13  is an exploded view of the band saw shown in  FIG. 1 . 
           [0021]      FIG. 14  is a cross section of the band saw of  FIG. 3  taken along line  14 - 14 . 
           [0022]      FIG. 15  is an enlarged view of a portion of the cross section of  FIG. 14 . 
           [0023]      FIG. 16  is a perspective view of a tensioning mechanism of the band saw shown in  FIG. 1 . 
       
    
    
       [0024]    Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. 
       DETAILED DESCRIPTION 
       [0025]      FIGS. 1-16  illustrate a band saw  10  having a frame or housing  12  according to one construction of the invention. The housing  12  includes a deck  14  supporting a motor  16  ( FIG. 14 ) and a gear box  18  and a blade guard  20  coupled to the deck  14 . In the illustrated construction, the motor  16  is configured as a DC motor, and the band saw  10  includes removable, rechargeable battery  22  to deliver power to the motor  16 . The motor  16  is enclosed by a housing  17 , preferably formed of plastic. The gear box  18  is preferably formed of a metal. Other suitable materials may be employed. 
         [0026]    The motor  16  is drivingly connected to a drive assembly  24  ( FIG. 14 ) at least partially housed within the gear box  18 . The drive assembly  24  may include any of a number of different gear train arrangements configured to provide a low-speed, high-torque output from the high-speed, low-torque input provided by the motor  16 . The motor  16  and the drive assembly  24  are operable to drive a continuous band saw blade  26  having a cutting edge  114  to cut a workpiece  28 . 
         [0027]    With particular reference to  FIGS. 1-3 , the housing  12  includes a single handle  30  supporting a trigger switch  32  to provide power to the band saw  10 . The switch  32  is operable to control operation of the motor  16 . Generally, the handle  30  is shaped and arranged for one-handed operation of the band saw  10  as the workpiece  28  is cut. The handle  30  includes a grip portion  34  adjacent the trigger  32 . The grip portion  34  is shaped for accommodating a gripping action by the user&#39;s hand during operation of the band saw  10 . 
         [0028]    In the illustrated construction, the battery  22  is a 12-volt power tool battery coupled to the handle  30 . The battery  22  is coupled to a portion of the handle  30  adjacent the grip portion  34 . The battery  22  is coupled to the handle  30  by inserting a portion of the battery  22  within a portion of the handle  30 , i.e., a cavity or recess  36  formed in the handle  30  for receiving the battery  22 . In further constructions, the battery  22  may be coupled to the handle  30  by sliding, snapping, rotating, or the like. The recess  36  also includes a terminal assembly (not shown) for electrically connecting the battery  22  to the band saw motor  16  via an electrical circuit (not shown). The battery  22  includes Lithium-ion battery cells. In other constructions of the band saw  10 , the battery  22  may have higher or lower nominal voltage. Additionally or alternatively, the battery cells may have chemistries other than Lithium-ion such as, for example, Nickel Cadmium, Nickel Metal-Hydride, or the like. In other constructions, other sources of power, such as a power cord to provide AC power to an AC motor, may be employed. 
         [0029]    With particular reference to  FIG. 3 , the housing  12 , and more particularly the deck  14  and the guard  20 , defines an opening or U-shaped cavity  38 . A first housing portion  40  is generally defined to one side of the opening  38  and a second housing portion  42  is generally defined to the opposite side of the opening  38 . The opening  38  receives the workpiece  28  and includes a cut zone  44  in which the workpiece  28  is cut by a portion of the band saw blade  26  that is located in the opening  38 . With particular reference to  FIG. 1 , the opening  38  is delimited by first and second parallel, facing planes  46 ,  48  that are substantially normal to the portion of the band saw blade  26  positioned in the opening  38 . The portion of the saw blade  26  positioned in the opening  38  defines a cutting axis C intersecting each of the planes  46 ,  48  and is oriented substantially normal to each of the planes  46 ,  48  between the respective planes  46 ,  48 . The opening  38  has a width W 1  defined as the perpendicular distance between the first and second planes  46 ,  48 . 
         [0030]    The handle  30  extends from a top of the deck  14  on a side of the deck opposite the cutting edge  114  of the blade  26 , and extends from the first housing portion  40  on one end and the second housing portion  42  on the other end. Thus, the handle  30  extends between the first housing portion  40  and the second housing portion  42 . The handle  30  is positioned at the rear of the band saw  10  opposite the cut zone  44 . The grip portion  34  is positioned substantially between the first and second planes  46 ,  48 . The grip portion  34  is adjacent the trigger  32  and configured to be grasped by an operator&#39;s hand. The trigger  32  is also at least partially positioned between the first and second planes  46 ,  48 . In other constructions, the trigger  32  may be positioned outside of the first and second planes  46 ,  48  and adjacent or near one of the first and second planes  46 ,  48 . 
         [0031]    Referring to  FIG. 5 , the band saw  10  includes a first guide roller set  50  disposed on one side of the cavity  38  adjacent the first plane  46  and on the first housing portion  40 , and a second guide roller set  52  disposed on an opposite side of the cavity  38  adjacent the second plane  62  and on the second housing portion  42 . Each of the guide roller sets  50 ,  52  includes a pair of aligned rollers  54 ,  56 , respectively, with which opposite sides of the saw blade  26  are engaged and a respective mounting block  58 ,  60  to which the rollers  54 ,  56  are rotatably supported. The mounting blocks  58 ,  60  are coupled to the deck  14  (e.g., using fasteners). The first and second guide roller sets  50 ,  52  support the band saw blade  26  as the blade  26  enters and exits the cut zone  44 . 
         [0032]    With reference to  FIG. 7 , the band saw  10  includes a drive wheel  62  and a driven wheel  64 . The drive wheel  62  is generally disposed in the first housing portion  40  and the driven wheel  64  is generally disposed in the second housing portion  42 . The drive wheel  62  rotates about a drive wheel axis  66  defined by a drive wheel axle  68  and is drivingly connected to the motor  16  via the drive assembly  24  in the gear box  18 . The driven wheel  64  rotates about a driven wheel axis  70  defined by a driven wheel axle  72  and is rotatably supported by the deck  14 . A distance D ( FIG. 1 ) between the driven wheel axis  70  and the drive wheel axis  66  is approximately 6.75 inches, and the drive and driven wheels  62 ,  64  each have a diameter of approximately 3.5 inches. In other constructions, the band saw  10  may be smaller or larger. 
         [0033]    A drive tire  74  and a driven tire  76  are coupled to the periphery of the respective drive wheel  62  and the driven wheel  64 . Each of the tires  74 ,  76  is a circular-shaped ring formed of a soft and/or flexible elastomeric material that is able to lock or adhere to the drive wheel  62  or the driven wheel  64 . The band saw blade  26  extends around the drive wheel  62  and the driven wheel  64  and grips the tires  74 ,  76  and, as a result, motion from the drive wheel  62  is transmitted to the band saw blade  26  via the wheel tires  74 ,  76 . 
         [0034]    With reference to  FIGS. 1 and 13-16 , the band saw  10  also includes a blade tensioning mechanism  78  coupled to the deck  14  to adjustably provide appropriate tension on the band saw blade  26 . The blade tensioning mechanism  78  is operable to move the driven wheel axle  72  closer to or farther away from the drive wheel axle  68  in order to decrease or increase the tension in the band saw blade  26 , respectively. Specifically, the blade tensioning mechanism  78  includes a lever  80  having a pivot axis  82  and an eccentric lobe  84  coupled to the lever  80  and defining a central axis  86  that is parallel to and non-coincident with the pivot axis  82 . 
         [0035]    The blade tensioning mechanism  78  also includes a spring guide  88 , preferably formed by stamping, having guide pins  90  formed as one piece therewith. The tensioning mechanism  78  also includes springs  92 , such as coil springs, each of which is disposed about one of the guide pins  90 , and a lobe guide  94  for receiving the eccentric lobe  84 . The lobe guide  94  is coupled to and positioned in sliding relationship with the guide pins  90  and is limited, or stopped, at one end of the guide pins  90  by stops  96 . One free end of each spring  92  abuts the spring guide  88  and another free end of each spring  92  abuts the lobe guide  94 . 
         [0036]    The driven wheel axle  72  is fastened to the spring guide  88  by way of a threaded fastener  98  and tilting blocks  100 ,  102 . The tilting blocks  100 ,  102  include angled seats  101 ,  103  ( FIG. 15 ), respectively, for receiving the threaded fastener  98  at a slight angle with respect to the drive wheel axis  66  for tiling the driven wheel axle  72  at the slight angle. For example, the driven wheel axle  72 , and therefore the driven wheel axis  70 , is tilted at an angle of about 1 to 3 degrees with respect to the drive wheel axis  66 , and preferably about 1.25 degrees. The tiling of the driven wheel  64  provides an improved grip between the band saw blade  26  and the tire  76 . 
         [0037]    When the lever  80  is rotated such that the eccentric lobe  84  moves in an arcuate path in a direction towards the drive wheel  62 , the eccentric lobe  84  pulls the lobe guide  94  towards the drive wheel  62 . The lobe guide  94  thereby abuts the stops  96  and pulls the spring guide  88  towards the drive wheel  62 , which pulls the driven wheel  64  towards the drive wheel  62 , thus creating slack in the blade  26 . Conversely, when the lever  80  is rotated such that the eccentric lobe  84  moves in an arcuate path in a direction away from the drive wheel  62 , the eccentric lobe  84  pushes the lobe guide  94  towards the springs  92 . The lobe guide  94  moves against the bias of the springs  92 , which in turn pushes the driven wheel  64  away from the drive wheel  62 , thereby creating tension in the blade  26 . 
         [0038]    With reference to  FIGS. 1-4 , the band saw  10  includes a bridge  104 , or workpiece guard, for limiting the range of movement of the workpiece  28  after a cutting operation. The bridge  104  includes a U-shaped member extending from the housing  12 , and specifically from the deck  14 , in a direction away from the blade  26 , or away from the opening  38 . The U-shaped member includes first and second portions  106 ,  108  extending from the deck  14  and a third portion  110  extending between the first and second portions  106 ,  108 . The first portion  106  extends from the deck  14  on the first housing portion  40  in a direction substantially perpendicular to the cutting axis C. The second portion  108  extends from the deck  14  on the second housing portion  42  in a direction substantially perpendicular to the cutting axis C. The third portion  110  extends between the first and second portions  106 ,  108  in a direction substantially perpendicular to the first and second portions  106 ,  108 . In other constructions, one of the first and second portions  106 ,  108  may be absent such that the third portion  110  is cantilevered from the other of the first and second portions  106 ,  108 . 
         [0039]    As is best illustrated in  FIG. 2 , the third portion  110  of the bridge  104  is disposed between an upper surface  112  of the deck  14 , i.e., the surface facing the handle  30 , and the handle  30 . The third portion  110  is positioned at a perpendicular distance from the cutting edge  114  ( FIG. 2 ) of the blade  26  at least equal to a width W 2  of the cut zone  44 . The width W 2  of the cut zone is defined as the perpendicular distance between a support surface  118  of a shoe  116  (which will be described in greater detail below) and the second plane  48 . As such, the workpiece  28  is provided with enough space for the cutting operation to be completed without the bridge  104  limiting the cut. In a preferred construction, the width W 2  is between approximately 1.5 and 1.8 inches, and is preferably approximately 1.65 inches. 
         [0040]    The bridge  104  spans the opening  38  between the first housing portion  40  and the second housing portion  42 , or, in other words, between the first and second planes  46 ,  48 . As best shown in  FIG. 5 , the bridge  104  is integrated, or formed as one piece, with the mounting blocks  58 ,  60  to which the guide roller sets  50 ,  52  are attached. This structure provides rigidity to the band saw  10  between the first housing portion  40  and the second housing portion  42 . In other constructions, the bridge  104  may be formed as a separate piece from the mounting blocks  58 ,  60  and may be coupled to the mounting blocks  58 ,  60  or coupled directly to the deck  14 . As best shown in  FIG. 4 , the bridge  104  is angled with respect to the drive wheel axis  66  at an angle similar to an angle of the blade  26  in the cut zone  44  and to an angle A of the handle  30  with respect to the drive wheel axis  66 . In one construction, the angle A is between approximately 20 and 35 degrees and is preferably approximately 27 degrees. Other suitable angles may be employed. 
         [0041]    The band saw  10  also includes a shoe  116  having a support surface  118  against which the workpiece  28  is abutted during a cutting operation. Best illustrated in  FIG. 10 , the shoe  116  is fastened to the band saw  10  by way of threaded fasteners  120 , such as screws. The bridge  104  includes a shoe-receiving boss  122  to which the shoe  116  is fastened by the screws  120 . The shoe-receiving boss  122  includes three apertures  123  for receiving the screws  120 , and the shoe  116  includes two apertures  125  for receiving the screws  120 , such that the shoe  116  is securable in two different positions with respect to the bridge  104 . 
         [0042]    With particular reference to  FIGS. 7-9 and 12-13 , the housing  12  includes the blade guard  20  pivotally coupled to the deck  14  for pivotal movement between a closed position ( FIG. 1 ) and an open position ( FIG. 7 ). In the illustrated construction, the blade guard  20  is formed as a separate piece from the deck  14  and is coupled to the deck  14  by way of a hinge  124  for pivotal movement relative to the deck  14 . The hinge  124 , such as a barrel hinge, includes barrel sections  126 ,  128  formed alternatingly with the deck  14  and the blade guard  20 , respectively, and a pin  130  ( FIG. 4 ) passing through the barrel sections  126 ,  128  and providing a pivot axis  132 . In the illustrated construction, the pin  130  is formed from metal, the deck  14  and barrel sections  126  are formed as one piece from a polymer, and the blade guard  20  and barrel sections  128  are formed as one piece from a polymer. In other constructions, other suitable materials may be employed. 
         [0043]    In the closed position, the deck  14  and the blade guard  20  cooperate to substantially enclose the band saw blade  26 , except the portion of the band saw blade  26  positioned in the cut zone  44  (i.e., the portion of the band saw blade  26  positioned in the opening  38  and between the first and second planes  46 ,  48 ). The portion of the blade  26  not positioned in the cut zone  44  is substantially enclosed, or inaccessible, when the housing  12  is in the closed position. The blade guard  20  includes a side wall  134  extending about the perimeter of the band saw blade  26 , and a bottom wall  136  extending from the side wall  134  to cover the cutting edge  114  of the band saw blade  26  and portions of the bottom of the drive and driven wheels  62 ,  64 . The bottom wall  136  includes first and second openings  138 ,  140  positioned centrally over portions of the drive and driven wheels  62 ,  64 , respectively. The openings  138 ,  140  are approximately centered about the drive axis  66  and the driven axis  70 , respectively ( FIG. 12 ). The openings  138 ,  140  are positioned proximate at least a portion of the drive and driven wheels  62 ,  64  respectively to allow chips and debris carried by the blade  26  an outlet from the housing  12 . 
         [0044]    With reference to  FIGS. 7, 9 and 12 , the blade guard  20  includes chip vents  144  adjacent the blade  26  as the blade exits the cut zone  44 . In the illustrated construction, the chip vents  144  are positioned on the first housing portion  40  proximate the drive wheel  62  and the shoe  116 . The chip vents  144  provide an outlet for chips and debris from the housing  12 . With particular reference to  FIGS. 7 and 9 , wear plates  146  are received on an inner surface of the blade guard  20  adjacent the cutting edge  114  of the blade  26  for preventing the blade  26  from cutting through the blade guard  20 . The wear plates  146  are preferably formed of a metal, such as steel or aluminum, or another suitable material that is harder than the material of the blade guard  20 . In the illustrated construction, the wear plates  146  are located on the second housing portion  42 , or driven wheel side of the blade guard  20 . In other construction, the wear plates  146  may additionally or alternatively be positioned on the first housing portion  40 , or drive wheel side of the blade guard  20 . 
         [0045]    A pair of latches  142  couple the blade guard  20  to the deck  14  in the closed position. The latches  142  are substantially mirror images of the each other. The latches  142  each include a deck lip  148  ( FIG. 13 ) generally extending from the deck  14  and disposed at outer ends of the latches  142  with respect to the opening  38 , a guard lip  150  extending from the blade guard  20  and disposed at inner ends of the latches  142  with respect to the opening  38  and a generally C-shaped latch member  152 . The latch members  152  are slidably coupled to the deck  14  such that they are slidable between a locked position ( FIGS. 1-4, 6, 12 ) in which the deck  14  and blade guard  20  are substantially fixed relative to one another and an unlocked position ( FIG. 7 ) in which the blade guard  20  is free to pivot away from the deck  14  on the hinge  124 . The latch members  152  slide in a direction generally perpendicular to the drive wheel axis  66 . 
         [0046]    With reference to  FIG. 7 , in the open position, the latch members  152  are positioned away from the opening  38  such that the latch members  152  engage, and are positioned about, the deck lips  148 . With reference to  FIG. 2 , in the closed position, the guard lips  132  are positioned towards the opening  38  such that the latch members  152  engage, and are positioned about, the guard lips  150  to lock the blade guard  20  to the deck  14 . In the closed position, the guard lips  150  are generally parallel and adjacent to the deck lips  148 . 
         [0047]      FIG. 6  illustrates a cross section of the latch  142  in which the latch member  152  is in the locked position. The latch  142  includes a detent mechanism  154  that provides a threshold force below which the latch member  152  will not slide between the locked and unlocked positions. The detent mechanism  154  includes first and second projections, ribs or bumps  156 ,  158 , respectively, formed on a surface, such as the upper surface  112 , of the deck  14 . A cantilevered spring arm  160  is formed on an inner surface of the latch member  152  facing the deck  14  and includes a projection  162  extending towards the deck  14 , and specifically towards the bumps  156 ,  158 . The projection  162  cooperates with the first and second bumps  156 ,  158  to provide the threshold force for sliding the sliding member between the locked and unlocked positions. The spring arm  160  deflects under a force greater than the threshold force such that the latch member  152  slides past the first bump  156  and subsequently the second bump  158  to the unlocked position. If the force applied is lower than the threshold force, the projection  162  abuts the first or second bump  156 ,  158  to inhibit the latch member  152  from sliding. 
         [0048]      FIGS. 7 and 11  illustrate a tire brush  164  formed from bristles made of a polymer, such as nylon. In other constructions, the bristles may be made of other polymers, metals and other suitable materials. The tire brush  164  is received in a bristle receptacle  166  extending from an inner surface of the blade guard  20  proximate the opening  138  for the drive wheel  62 . The tire brush  164  is positioned in contact with the drive wheel tire  74  to clean chips and debris from the drive wheel tire  74 . The tire brush  164  is sandwiched within the receptacle  166  and secured in place by a cap  168  fastened to the receptacle  166  by a fastener  170 , such as a screw. The screw  170  and cap  168  are readily removable when the blade guard  20  is open for easy replacement of the tire brush  164 . 
         [0049]      FIG. 13  illustrates an exploded view of the band saw  10 . The band saw  10  includes a reinforcement plate  172  formed of a metal and disposed between the deck  14  and the wheels  62 ,  64  for providing rigidity to the housing structure  12  of the band saw  10 . The reinforcement plate  172  includes a drive portion  174  located proximate the drive wheel  62 , a driven portion  176  located proximate the driven wheel  64  and a bridge portion  178  extending between the drive and driven portions  174 ,  176 . The drive wheel  62  is positioned adjacent a bottom surface of the drive portion  174  and the driven wheel  64  is positioned adjacent a bottom surface of the driven portion  176 . The drive portion  174  is secured to the gear box  18  by fasteners such as screws (not shown). The gear box  18  is, in turn, fastened to the deck  14 . The driven portion  176  is fastened to the deck  14  by fasteners, such as screws (not shown). The drive portion  174  includes an aperture  180  for receiving the drive wheel axle  68  therethrough, and the driven portion  176  includes a slot  182  for receiving the driven wheel axle  72  therethrough and accommodating movement of the driven wheel axle  72  as a result of the tensioning mechanism  78 . 
         [0050]    The tensioning mechanism  78  is trapped in a space between the driven portion  176  of the reinforcement plate  172  and an inner surface of the deck  14 . With reference to  FIGS. 14 and 15 , a distal end of the spring guide  88  abuts the reinforcement plate  172  to inhibit the tensioning mechanism  78  from tilting in a first direction, and the tilting block  100  bears against a metal insert  184 , which is coupled to the deck  14  ( FIG. 13 ) to inhibit the tensioning mechanism  78  from tilting in a second direction opposite the first direction. Thus, the tensioning mechanism  78  is trapped between the reinforcement plate  172  and the guard  14 . 
         [0051]    In operation of the band saw  10 , an operator grips the grip portion  34  of the handle  30  with one hand and actuates the trigger  32  with the same hand. Actuation of the trigger  32  causes the motor  16  and drive assembly  24  to rotate the drive wheel  62  about the drive wheel axis  66 , causing motion of the band saw blade  26  for cutting the workpiece  28  in the cut zone  44 . Because the grip portion  34  is positioned at least partially between the first and second planes  46 ,  48  bounding the cut zone  44 , or opening  38 , the operator&#39;s hand is also positioned between the first and second planes  46 ,  48  during the cutting operation. The bridge  104  limits movement of the workpiece  28  after the cutting operation is complete. Furthermore, the guard  20  protects the cutting edge  114  of the blade  28  when the cutting edge  114  is not positioned in the cut zone  44 . 
         [0052]    Thus, the invention provides, among other things, a compact band saw having a workpiece guard and a blade guard. Various features and advantages of the invention are set forth in the following claims.