Hercules Band Saw

When I first stepped into the world of woodworking and metalcraft, I was overwhelmed by the sheer variety of tools claiming to be “essential” for my workshop. Five years and countless projects later, I can confidently say that investing in a quality band saw was the single best decision I made for my crafting journey. Today, I want to walk you through everything you need to know about the Hercules Band Saw—a tool that has transformed my workshop capabilities without emptying my wallet.

Whether you’re a seasoned craftsperson looking to upgrade or a beginner weighing your options, this comprehensive guide will help you understand if the Hercules Band Saw deserves a place in your workshop. Let’s cut through the marketing noise and get to what really matters.

What Exactly Is the Hercules Band Saw and What Can It Do?

The first time I saw a band saw in action, I was mesmerized by its precision and versatility. Unlike circular saws that power through materials with brute force, band saws use a continuous loop of toothed metal—the band—that runs around two or three wheels to create smooth, controlled cuts.

The Hercules Band Saw specifically refers to the line of band saws produced under the Hercules brand, which has gained popularity among DIY enthusiasts and professionals alike. What makes these tools stand out is their balance between affordability and capability.

In my workshop, I’ve used my Hercules for:

• Creating intricate curved cuts in hardwood for custom furniture pieces
• Resawing thick lumber into thinner boards (a game-changer for maximizing expensive hardwoods)
• Cutting precise joints that would be impossible with handsaws
• Making quick work of plastic piping for home improvement projects
• Even cutting non-ferrous metals when equipped with the right blade

The beauty of the Hercules is that it occupies a sweet spot in the market—more robust than entry-level models that struggle with hardwoods, but without the eye-watering price tag of premium industrial models.

Hercules vs. The Competition: How Does It Stack Up?

When I was researching band saws, I spent weeks comparing specifications, reading reviews, and even visiting local workshops to see different models in action. Here’s how the Hercules compares to other popular brands:

Hercules vs. DeWalt

DeWalt has long been the go-to brand for professionals, and their band saws reflect that pedigree. They typically offer more powerful motors and heavier-duty construction than the Hercules. However, this comes at a significant price premium—often 30-40% more for comparable cutting capacities.

What surprised me most was how close the Hercules came to matching DeWalt’s performance in real-world cutting tasks. While the DeWalt might power through hardwoods slightly faster, the Hercules never left me wanting for more power in my everyday projects.

Hercules vs. Ryobi

On the more budget-friendly end, Ryobi offers several band saw models that compete directly with Hercules on price. In my experience (and from talking with other woodworkers), the Hercules edges out Ryobi in three key areas:

1. Build quality and durability—my friend’s Ryobi developed alignment issues after just six months
2. Motor consistency—the Hercules maintains speed under load better
3. Precision of fence and guide systems—critical for accurate cuts

The Ryobi isn’t a bad choice for occasional use, but if you’re planning regular projects, the extra investment in a Hercules pays dividends in reliability.

Hercules vs. Jet and Grizzly

Moving up the price ladder, brands like Jet and Grizzly offer band saws that definitely outperform the Hercules in heavy-duty applications. Their cast iron tables, more powerful motors, and precision-engineered components make them the choice for production workshops.

But here’s the reality check: these premium models start at nearly triple the price of the Hercules. For my small workshop and mixed-use projects, I couldn’t justify the extra expense for capabilities I rarely need.

The Key Features That Make the Hercules Band Saw Stand Out

After using my Hercules for over three years now, several features have proven especially valuable:

Cutting Capacity

The standard Hercules models offer a 9-inch throat capacity (the distance from the blade to the vertical frame). This has been more than adequate for 90% of my projects, including furniture components and decorative pieces.

For resawing (cutting boards into thinner slices), the Hercules provides about 4.5 inches of vertical cutting capacity. While commercial sawmills might scoff at this, it’s perfect for preparing stock for small to medium-sized projects.

Motor Power and Performance

The 2.5 amp motor found in most Hercules models strikes an excellent balance between power consumption and cutting ability. I’ve successfully cut through 3-inch thick maple without any bogging down—though I wouldn’t recommend pushing it much beyond that regularly.

What impresses me most is how the motor maintains consistent power throughout extended cutting sessions. Lesser band saws often suffer from performance degradation as they heat up.

Table and Fence System

The cast aluminum table on the Hercules provides a smooth, flat surface that supports workpieces evenly. It tilts up to 45 degrees for angled cuts—a feature I’ve used countless times for decorative edges on box lids and custom picture frames.

The included rip fence locks firmly in place and remains parallel to the blade, which is crucial for straight cuts. After minimal adjustment out of the box, mine has held its settings reliably through years of use.

Blade Guides and Tension System

One area where band saws often reveal their quality is in the blade guidance system. Cheaper models use simple pins that allow too much blade wandering, while the Hercules employs ball-bearing guides above and below the table.

The tension adjustment mechanism uses a quick-release lever that makes blade changes straightforward—a feature I greatly appreciate when switching between fine-detail work and resawing tasks.

Metal Cutting Capabilities: Can the Hercules Handle It?

A question I frequently get from friends considering a band saw purchase is whether it can cut metal. The answer is yes, but with important qualifications.

The Hercules Band Saw can effectively cut:

• Aluminum (even thicker pieces, with the right blade)
• Brass and copper
• Thin mild steel (up to about 1/8 inch with proper setup)

However, it’s not designed for heavy-duty metal cutting. For occasional metal work, I’ve found that installing a bi-metal blade with 14-18 teeth per inch and reducing the cutting speed (if your model has variable speed) produces clean cuts without damaging the saw.

I remember tackling a project that required cutting several aluminum brackets. After installing the appropriate blade and taking my time with the feed rate, the Hercules performed admirably—much better than trying to use a hacksaw manually!

For those primarily interested in metalworking, specialized metal-cutting band saws with proper cooling systems would be a better investment. But for mixed-media crafters like myself, the Hercules’ ability to handle both wood and non-ferrous metals with a blade change is a tremendous advantage.

Where to Buy and What to Expect to Pay

The Hercules Band Saw is primarily distributed through Harbor Freight Tools, both in their physical stores and online. Occasionally, you might find them through third-party sellers on platforms like Amazon or eBay, though I’d recommend caution with these sources as warranty coverage may be affected.

As for pricing, expect to pay between $179.99 and $349.99 depending on the specific model and any promotions running at the time. Harbor Freight frequently offers coupons and sales that can bring the price down significantly—I saved about 15% by timing my purchase with their annual tool sale.

For those on a budget, Harbor Freight sometimes offers refurbished or open-box units at their physical locations at further discounted prices. Mine was a display model that I got for $50 less than retail, and it has performed flawlessly.

Understanding Blade Requirements for Your Hercules Band Saw

Selecting the right blade for your Hercules is crucial for achieving optimal results. The standard blade dimensions vary slightly between models, but most Hercules band saws accept:

• Length: 62-64 inches (always check your specific model’s requirements)
• Width: 1/8 inch to 3/8 inch
• Thickness: 0.014 to 0.025 inches

For different applications, I recommend:

• General woodworking: 3/8″ blade with 4-6 TPI (teeth per inch)
• Intricate curves: 1/8″ or 1/4″ blade with 6-10 TPI
• Metal cutting: 1/4″ bi-metal blade with 14-18 TPI
• Resawing thick lumber: 1/2″ blade with 3-4 TPI (if your model accepts this width)

One piece of advice from personal experience: don’t skimp on blade quality. I initially tried to save money with bargain blades, only to find they dulled quickly and produced wavy cuts. Investing in premium blades from manufacturers like Olson or Starrett has dramatically improved my results and actually saved money in the long run as they last significantly longer.

Versatility: Working with Both Wood and Metal

The dual-purpose capability of the Hercules Band Saw is one of its greatest strengths. With a simple blade change, you can transition from precise woodworking to cutting metal components.

For woodworking, the Hercules excels at:

• Cutting curves and irregular shapes
• Resawing boards for book-matching or maximizing expensive lumber
• Creating tenons and other joinery components
• Trimming veneer and thin stock without splintering

When equipped for metalworking, it can handle:

• Aluminum extrusions for DIY projects and frames
• Brass and copper for decorative elements
• Thin sheet metal for custom brackets and mounts
• Plastic materials like PVC and acrylic

This versatility was particularly valuable when I was building a custom desk with a mixed-media design. Being able to cut both the walnut frame components and the aluminum accent pieces on the same machine saved me significant time and ensured the parts fit together perfectly.

Warranty Coverage and Support

Hercules band saws typically come with a 90-day satisfaction guarantee and a limited two-year warranty covering defects in materials and workmanship. While this isn’t as comprehensive as the three to five-year warranties offered by premium brands, it has proven adequate in my experience.

When I encountered an issue with my blade guide bearing after about 18 months of ownership, Harbor Freight’s customer service was surprisingly responsive. They shipped a replacement part at no cost, along with clear instructions for installation.

For those concerned about longer-term support, I’d recommend:

1. Registering your product immediately after purchase
2. Keeping all original packaging and documentation
3. Performing and documenting regular maintenance
4. Taking photos of your receipt and storing them digitally

The fact that Hercules is a Harbor Freight house brand means replacement parts tend to be readily available and reasonably priced even beyond the warranty period.

The Pros and Cons of Choosing a Hercules Band Saw

After extensive use, here’s my honest assessment of the Hercules Band Saw’s strengths and limitations:

Pros:

• Excellent value-to-performance ratio
• Versatile cutting capabilities across materials
• Solid construction for the price point
• Readily available replacement parts
• Good blade tracking and tension systems
• Smooth, vibration-free operation
• Effective dust collection port
• Compatible with standard blade sizes

Cons:

• Limited vertical cutting capacity compared to larger models
• Table size is adequate but not generous
• Some plastic components in non-critical areas
• Assembly instructions could be clearer
• Miter gauge is basic and might need upgrading for precision work
• Light duty cycle (not intended for all-day industrial use)
• Limited speed adjustment on base models

For my mixed hobby and small business needs, the pros have far outweighed the cons. The limitations only become apparent in very specific scenarios that most home workshops rarely encounter.

Blade Replacement: A Step-by-Step Guide

Replacing the blade on a Hercules Band Saw is a straightforward process that becomes second nature with practice. Here’s my method:

1. Unplug the saw for safety (never skip this step!)
2. Release the blade tension using the quick-release lever
3. Remove the table insert for better access
4. Open both wheel covers by loosening the thumb screws
5. Carefully remove the old blade, wearing gloves to protect against sharp teeth
6. Install the new blade, ensuring the teeth point downward toward the table
7. Center the blade on both wheels
8. Apply light tension and manually rotate the top wheel to ensure the blade tracks properly
9. Adjust the upper and lower blade guides to support the new blade
10. Restore full tension according to the blade width
11. Close the wheel covers and replace the table insert
12. Plug in and test with a scrap piece before making important cuts

The whole process takes me about 5-7 minutes now. One tip: I keep a small notebook in my workshop where I record the tension settings that work best for different blade types. This reference has saved me considerable time and frustration when switching between tasks.

Understanding the Cutting Capacity

The cutting capacity of the Hercules Band Saw is defined by two key measurements:

1. Throat capacity: The distance from the blade to the vertical frame (typically 9-10 inches on standard Hercules models)
2. Resaw capacity: The maximum height of material you can cut (approximately 4.5 inches)

These dimensions determine the largest piece of material you can work with. For context, I’ve successfully used my Hercules to:

• Resaw 4-inch wide oak boards into 1/4-inch thick panels for cabinet doors
• Cut complex curves in 2-inch thick maple for chair components
• Create 8-inch diameter circles from 3/4-inch plywood for project bases

While these capacities won’t accommodate large furniture components or sizeable lumber processing, they cover the vast majority of hobbyist and small business needs. I’ve built hundreds of projects without ever feeling limited by these dimensions.

Portability Considerations

The standard Hercules Band Saw weighs approximately 60-70 pounds, depending on the specific model. While this isn’t lightweight, it’s still manageable for occasional repositioning in your workshop.

For enhanced portability, consider:

• Adding a mobile base with locking casters
• Mounting the saw on a dedicated cart with storage for blades and accessories
• Using a purpose-built workstation that accommodates multiple tools

I opted for a DIY solution—building a custom cart with storage underneath and locking wheels that allow me to move the saw when needed but keep it stable during operation. This setup has proven invaluable for my limited workshop space.

For those needing true portability between job sites, Hercules does offer a compact benchtop model that weighs significantly less. However, this comes with reduced cutting capacity and power.

Speed Control Options: Finding the Right Setting

Depending on the specific Hercules model, you may have variable speed options or a single-speed motor. The standard models typically operate at around 2,500 feet per minute (FPM), which is ideal for most woodworking applications.

If your model includes variable speed control, you’ll gain significant advantages when working with different materials:

• 1,500-1,800 FPM: Ideal for non-ferrous metals and hard plastics
• 2,000-2,500 FPM: Perfect for hardwoods and general woodworking
• 2,500-3,000 FPM: Best for softwoods and aggressive cutting

My model has a three-position switch that provides low, medium, and high speeds. I’ve found that medium speed handles about 80% of my projects effectively, with low speed reserved for metal and dense hardwoods, and high speed for softwoods and plywood.

If your budget allows, I’d recommend selecting a Hercules model with variable speed capabilities, as this flexibility greatly expands the range of materials you can work with effectively.

Band Saw vs. Scroll Saw: Understanding the Difference

A common point of confusion for new woodworkers is understanding the difference between band saws and scroll saws. Having used both extensively, here’s how they compare:

The Hercules Band Saw:

• Uses a continuous loop blade
• Makes both straight and curved cuts
• Handles thicker materials (up to 4.5 inches)
• Creates smoother, more consistent cuts
• Excels at resawing and ripping operations
• Less suited for extremely intricate interior cuts

Scroll saws:

• Use a reciprocating blade
• Specialize in intricate interior cuts (can remove the blade to thread through drilled holes)
• Generally limited to materials under 2 inches thick
• Create more detailed curves and corners
• Produce more vibration during cutting
• Less effective for straight-line cutting

In my workshop, I use the band saw for about 80% of my curved cutting needs and only switch to the scroll saw when I need to create interior cutouts or extremely tight curves. If you’re just starting out and can only afford one tool, the band saw offers far more versatility and practicality for most projects.

User Reviews and Community Feedback

Before purchasing my Hercules, I scoured online forums, YouTube reviews, and woodworking communities for honest feedback. The consensus was remarkably consistent:

The Hercules Band Saw received strong positive reviews for:

• Value for money
• Cutting performance in wood
• Ease of blade changes
• Build quality relative to price
• Smooth operation with minimal vibration

Common criticisms centered around:

• Basic fence quality (though many users upgrade this)
• Limited included documentation
• Occasional alignment issues out of the box
• Light-duty nature compared to industrial models

After owning mine for several years, I find these assessments accurate. The machine performs well above its price point for most applications, with limitations only becoming apparent in heavy-duty or production environments.

One review that particularly resonated with me came from a professional carpenter who wrote: “The Hercules isn’t trying to be a $1,200 industrial saw. It’s giving home workshops and small businesses 80% of that capability at 25% of the price. For what it aims to be, it excels.”

Professional Use: Is the Hercules Up to the Task?

Whether the Hercules Band Saw is suitable for professional use depends entirely on your specific requirements and volume of work.

For my small custom furniture business, which produces 3-5 commissioned pieces per month, the Hercules has proven more than adequate. It handles all the curved components, resawing, and detail work without issue.

However, I would hesitate to recommend it for:

• Production environments with continuous daily use
• Businesses primarily focused on resawing thick hardwoods
• Shops requiring precise repetitive cuts without fence upgrades
• Metal fabrication as a primary function

The Hercules occupies a middle ground—more capable than purely hobbyist tools but not engineered for industrial workloads. For small businesses, solo artisans, and serious hobbyists, it offers an excellent balance of capability and affordability.

One professional woodturner I know uses his Hercules exclusively for preparing bowl blanks from raw lumber—a demanding task that involves cutting through wet, dense hardwoods. After three years of regular use, his only maintenance has been blade replacements and occasional bearing lubrication.

Included Accessories and Recommended Additions

Out of the box, the Hercules Band Saw typically includes:

• The band saw with pre-installed blade
• A basic rip fence
• Miter gauge for angled cuts
• Blade tracking window
• 2.5-inch dust port adapter
• Assembly hardware and wrenches
• Owner’s manual

While these basics get you started, I’ve found several accessories worth adding:

1. Upgraded rip fence: Aftermarket options from Kreg or Shop Fox provide greater stability and adjustability
2. Mobile base: Adding mobility to your setup makes workshop organization much easier
3. LED work light: Improves visibility for detailed cutting
4. Push blocks and sticks: Essential safety items when working with smaller pieces
5. Blade cleaning kit: Extends blade life by removing pitch and resin buildup
6. Assorted blades: Having 1/8″, 1/4″, and 3/8″ blades ready to go increases versatility

My most valuable addition has been a zero-clearance table insert that I made myself from 1/4-inch hardboard. This simple upgrade dramatically improves cut quality by supporting the material directly at the cutting point, preventing thin pieces from being pulled into the throat opening.

Maintenance and Cleaning: Keeping Your Hercules Running Smoothly

Proper maintenance has kept my Hercules Band Saw running like new for years. Here’s my routine:

Daily (or per use):

• Clear sawdust from the table and around the blade
• Check blade tension and tracking
• Inspect blade guides for proper adjustment
• Empty dust collection if used

Monthly:

• Clean the wheels and remove built-up sawdust from internal components
• Check drive belt tension (if applicable to your model)
• Apply a light coat of paste wax to the table surface for smoother feeding
• Verify all fasteners are tight
• Clean or replace the air filter on the motor housing

Quarterly:

• Remove and clean the blade with blade cleaner or simple Green solution
• Lubricate guide bearings with a drop of light machine oil
• Check alignment of wheels and adjust if necessary
• Inspect wiring and electrical components for wear
• Clean and dress the tires on the wheels if they show signs of glazing

This maintenance schedule takes minimal time but pays enormous dividends in performance and longevity. I’ve known workshop owners who neglected these basics and ended up with premature bearing failures or alignment issues that affected cut quality.

Material Versatility: What Can You Cut?

The range of materials that the Hercules Band Saw can effectively cut is impressive. In my projects, I’ve successfully worked with:

Woods:

• Softwoods (pine, cedar, fir)
• Hardwoods up to very dense species like ipe and purpleheart
• Plywood and manufactured boards
• Green (unseasoned) lumber
• Exotic hardwoods like padauk and zebrawood

Metals (with appropriate blades):

• Aluminum (solid and extrusions)
• Brass and copper
• Bronze
• Thin mild steel (up to 1/8″)
• Sheet metal

Other Materials:

• Acrylic and plexiglass
• PVC and other plastics
• Bone and antler (for knife handles and decorative inlays)
• Composite materials like Corian
• Foam insulation board for pattern making

The key to success with diverse materials is matching the blade type, tooth configuration, and cutting speed to the specific material. For instance, when cutting acrylic, I use a fine-tooth blade (10-14 TPI) at medium speed to prevent melting and chipping.

One particularly challenging project involved cutting 1/4-inch aluminum plate for custom light fixtures. By using a high-quality bi-metal blade with 18 TPI, reducing the speed to the lowest setting, and applying a stick lubricant directly to the blade, the Hercules handled this demanding task admirably—though I wouldn’t want to do it all day.

Making Your Final Decision: Is the Hercules Right for You?

After covering every aspect of the Hercules Band Saw in detail, the ultimate question remains: is it the right choice for your needs?

Based on my experience, the Hercules Band Saw is ideal for:

• Woodworking enthusiasts building furniture and decorative projects
• DIYers who need versatility across different materials
• Small business owners with moderate production requirements
• Makers with limited workshop space
• Those seeking a balance between performance and affordability
• Mixed-media artists working across wood, metal, and plastics

You might want to consider other options if:

• Your primary focus is production-level resawing of thick hardwoods
• You’re cutting metal as your primary application
• You need to cut exceptionally thick materials (beyond 4.5 inches)
• You require industrial-grade durability for all-day, everyday use
• Budget is no object and you want premium features

For my own needs—creating custom furniture, household projects, and occasional commissioned pieces—the Hercules has proven to be the perfect middle ground between entry-level models that would struggle with hardwoods and industrial behemoths that would strain both my budget and workshop space.

Conclusion: A Worthy Workshop Investment

Looking back on three years with my Hercules Band Saw, I can confidently say it has transformed what I’m able to create in my workshop. From precise curved cuts in thick hardwood to resawing expensive lumber into book-matched panels, this versatile tool has expanded my capabilities in ways I hadn’t anticipated.

While no tool is perfect, the Hercules offers an impressive balance of performance, versatility, and value that makes it accessible to serious hobbyists and small businesses alike. The limitations it does have are reasonable given its price point, and most can be addressed with simple upgrades or technique adjustments.

If you’re standing at the crossroads of a band saw purchase decision, weighing the endless options and conflicting reviews, I hope my experience helps clarify what you can realistically expect from the Hercules. For those seeking professional-adjacent performance without the professional-level price tag, the Hercules Band Saw represents one of the best values in today’s tool market.

Whether you’re cutting your first curved project or advancing your workshop capabilities, the Hercules offers a compelling blend of features that can grow with your skills and ambitions. After all, the best tool isn’t necessarily the most expensive—it’s the one that reliably helps you bring your creative vision to life.