Lucas Sawmill Is Small But Mighty


Scott Wunder of WunderWoods laying on giant white pine live natural edge milling

My sawmilling adventures began with an Alaskan chainsaw mill, which is just an attachment for a chainsaw to allow it to repeatedly cut a log lengthwise into lumber. It wasn’t anything fancy, and while it produced fine lumber, it was painfully slow to use. It didn’t take too many hours of me directly sucking in sawdust and fumes, while sweating my butt off, to start shopping for a more capable sawmill.

When I started my search, I considered bandsaws made by companies smaller than Wood-Mizer or TimberKing or Baker in a quest to also find smaller prices. While searching, I found several mills that looked suitable in the $5,000-$10,000 range, and I also came across a new “swing mill” from Australia called a Lucas mill.

The bandsaws looked to be a good choice as far as production went, but I didn’t have any way to move logs at the time, so the Lucas won out. It’s ability to easily break down and set up on site, while fitting in the bed of a pickup truck made it the clear choice, especially for larger logs. I say clear choice, but it wasn’t an easy choice. I didn’t like that the basic mill, fitted with a circular blade, was limited to 6″ or 8″ wide lumber without the optional slabbing bar attachment. And, my biggest fear was that this new mill from Australia, that I knew nothing about, might not be as good as it appeared in the videos.

Unfortunately, my fears were NOT immediately allayed. I went to pick up the more than $10,000 sawmill at the shipping terminal, and I couldn’t help but feel like I way overpaid for the amount of merchandise I picked up (Did I mentioned that it fits in the bed of my pickup truck?). There was only a sawhead, two long rails, and a few other miscellaneous metal parts that formed the frame ends. Besides that, the kit included a sharpener and some other odds and ends, but none of it added up to very much. I started doing the cost per piece arithmetic in my head, and it wasn’t looking good.

Here I am reading directions and setting up the 6" Lucas mill for the first time.

Here I am reading directions and setting up the 6″ Lucas mill for the first time.

Regardless of my buyer’s remorse, I was tickled to have a “real” sawmill and set it up in my back yard the very first chance I got. After just a short time reviewing the directions, I had the sawmill set up and ready to cut. Even for someone who had never set one up, the Lucas went together fast. It was then that I realized what I had paid for. I didn’t pay for lots and lots of parts and extra bulk. I paid for an impressively designed machine, with an amazingly small stature, than can tackle the biggest logs. I paid for all of the research and design that went into the mill by the Lucas boys, and I paid to not lug around thousands of extra pounds, and I paid for everything to go together with minimal effort and a minimal number of steps. I got all of that and more.

From a design standpoint, I can confidently say that every part of the Lucas mill is well-planned and simplified beyond belief. The only mechanisms that I have ever had a problem with are the winches that raise and lower the ends of the long rails. They work perfectly fine and they are quite smooth, but they can be dangerous. When fully loaded with weight, it is possible to release the winch and lose control, resulting in a violently swinging handle that can smash your arm and allow the sawhead to come crashing down. I know from personal experience, as this has happened to me more than once, with the last instance leaving me at the hospital with a possible broken arm (luckily it was just a very bad contusion). If they were to ask, I would recommend that the winch system be built like the raising and lowering mechanism on my TimberKing 1220 manual mill, which magically is able to easily raise and lower the sawhead with complete control and without the possibility of having a disastrous crash. I have no idea how it works, but it smoothly operates the sawhead with a very heavy 15 hp electric motor attached to it like it isn’t there at all.

Even logs this size, like the one I milled for Martin Goebel of Goebel and Co. Furniture can be milled with the Lucas mill.

Even logs this size, like the one I milled for Martin Goebel of Goebel and Co. Furniture can be milled with the Lucas mill.

Now that you know to watch your arm and to be careful when lowering the sawhead on the Lucas mill, I can continue telling you how wonderful the Lucas mill is. First off, realize that I bought a Lucas mill in 1995, so I have been using one for about 2o years now, and I still use it on a regular basis. It is a very versatile machine that can handle big logs with ease. I often get asked how big of a log I can handle, and with the Lucas mill in my corner, I can just answer, “Yes.”

Currently, I use the 8″ model, which means that with the 21″ diameter circular blade attached it can produce up to 8″ x 8″ dimensional lumber. I rarely cut 8″ x 8″, but the mill can easily be adjusted to cut any dimensions under 8″. I often cut 1″ and 2″ thick lumber by 8″ wide.

The Lucas mill is called a “swing” mill because the blade can flip or swing with the pull of a lever from the horizontal to vertical position and right back again. The cool part is that both of the cuts line up with each other and work in concert to produce accurate and straight, completely edged lumber without a dedicated edger or any extra handling. In contrast, to edge lumber on a bandsaw mill requires flitches (lumber with bark edges) to be stood up in the mill and cut one or two more times to produce lumber with four square edges.

In the 1990's, I used the 6" Lucas mill to produce lots of 1" thick, fully-edged lumber.

In the 1990’s, I used the 6″ Lucas mill to produce lots of 1″ thick, fully-edged lumber.

When cutting dimensional lumber I can easily work by myself making the vertical cut walking backward, then making the horizontal cut walking forward and finishing by sliding the cut board backward and out of the way. After a quick repositioning of the sawhead and a flip of the blade, I am back to cutting another piece of lumber. When cutting dimensional lumber like this I get in a rhythm–walk backward, flip blade, walk forward, slide board, move and flip blade, then repeat. The first cuts on the outside of the log are firewood, but after one pass across the top of the log and then dropping the mill to the next set of cuts, almost every pass produces an edged piece of lumber.

Scott Wunder of WunderWoods milling a large white oak slab on the Lucas mill for Martin Goebel of Goebel and Co. FurnitureWhen I first got my Lucas mill I used it with the circular blade most of the time. Everything I produced was fully edged. Big slabs weren’t in style, so I didn’t even own a slabber, let alone use one. Now things are different. Live edges are in and so are big slabs, so the slabber is on the mill most of the time. The slabber is an attachment that turns the sawhead into a giant 2o hp chainsaw mill, with a maximum cut of 64″ wide.

I use the Lucas mill with the slabber attachment to cut all of my big logs that will produce slabs for table tops. With the slabber attachment the Lucas is not fast, but it can cut much wider than my bandsaw mill (maximum cut of 29″ wide), and it doesn’t make sporadic wavy cuts like the bandsaw mill. Knowing that I won’t get a miscut on a high-priced piece of wood gives me a great piece of mind.

The Lucas mill is great at flattening live edge slabs too.

The Lucas mill is great at flattening live edge slabs too.

These days when the slabbing attachment isn’t on the mill, the circular blade is, but not for milling lumber. I have been using it to flatten my kiln-dried slabs, and as long as the blade is sharp, it works great. After I move the slab into position, I just skim the surface with the mill to remove the high spots. Next, I flip the slab, drop the mill a bit and skim the other side. The end result is a perfectly flat slab, ready for final planing. The kids at Lucas sell planing and sanding attachments, but I haven’t used or purchased either one since I finish almost all of the slabs with the power hand planer or wide-belt sander.

Every time I use the Lucas mill, I am reminded how well it works, from quickly setting it up to making small adjustments, everything is simple. And, I know when I show customers how capable it is, they are impressed that such a lightweight, easy-to-setup mill can do so much.

Note: While Lucas is more than welcome to pay me to endorse their mills, as of now they do not. This was written for educational purposes and to let others know how my slabs are produced.

 

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About wunderwoods

Hi! My name is Scott Wunder and I am the owner of WunderWoods Custom Woodworking. We build wine cellars, built-ins and furniture from local woods, here in St. Louis, MO. Recently, I finished a three-year term as the President of the St. Louis Woodworkers Guild, which had me writing a monthly article for our newsletter. I love to write, especially about wood, and found that I still had more to say. Every day I run into something wood related that I realize some of my customers don't know and this seems like a great forum for sharing what I have learned (instead of telling the same story to each person). The main thing to remember is that I try to keep it light and as my wife always reminds people that have just met me, "He is joking."

One response to “Lucas Sawmill Is Small But Mighty”

  1. kevin says :

    Excellent post,,,thank you!

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