Please show me how you used bearings for a more conventional power hack saw.
The type where the frame holding the blade slides forward and back wards.
to answer question #1 (..If I want to make the legs stiffer, do I weld another piece if angle to the leg, forming a box or just use a piece of 30 x 30 solid. I have to go and buy either.)
which ever way you are most comfortable with will be just fine. to box the existing legs you merely need to stitch weld a piece of angle to the existing legs extending almost to the hole where the blade mount bolt is . to replace with a hollow box tube you would need to remove the existing legs and replace them.
question #2 I'm not sure
question #3 (To reduce the speed of the motor I will used an idler shaft with pulleys, Will a piece of normal 20mm mild steel be ok for this shaft.)
This would depend largely on the the length of the shaft my old saw has a 2 shafts a 3/4" (19 mm) and a 7/8" (22 mm) mild steel idler shafts but it also uses a 1 1/4" (30 mm) x 16" (400 mm) by .090" ( 2.2mm ) blade with a 12" (300 mm) stroke and a 300 watt 1725 RPM motor
Never try to tell me it can't be done
When I have to paint I use http://kbs.justoldtrucks.com/
#1 I would start with adding the angle iron to make a solid square tube.
#2 Your motor is DC no? Just reverse the negative and positive wires will reverse the rotation.
#3 The size of shaft can be what ever you have on hand because there is not any resistance that would cause twist. And twist is the only thing to look at in a shaft.
I like that way you are looking to make adjustments to make what you have better. Anything you do can be reversed even if it is welded. I might suggest not reducing the speed and if you are trying to get more RPM's, I do not believe that small motor has enough torque. If that is your thoughts and you proceed when you get it going make sure to take notice of the heat on the motor. If it heat up too much it will cook itself.
Good luck and keep up posted.
It is almost impossible to use bearings like a band saw uses. The bearings would need to be in front and behind the material being cut. Which would cut down the ability to cut larger sizes of material. I believe you are fighting yourself because of the rigidity of the angle iron. Your saw will cut but to get a very accurate cut is going to be almost impossible. That is the reason I sent you all all the different plans. My saw is nearing the mid way and I'll share it when I finish.
If you still have my email send me a email and I show some of what I have.
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