Bandsaw Box

A Bandsaw Box is a fun small project that can utilize small pieces of scrap wood that would otherwise not be useable.  You have unlimited creativity in the size and shape of the overall box, the shape of the drawer, and the shape of the drawer pull or handle.

Bandsaw boxes make for a very unique and eye-catching storage piece that will generate questions and interest from those who see it.  They can be used to store any small items such as keys, jewelry, or cash!

Please see the links below for several helpful videos that provide good intstruction AND good examples of different styles of Bandsaw Boxes:

https://www.youtube.com/watch?v=JtJ3OOpp4Dw

https://www.youtube.com/watch?v=5Yhc2n4KEnI

https://www.youtube.com/watch?v=2PCN6MdbPgw

https://www.youtube.com/watch?v=S4e3uT4EDM0

https://www.youtube.com/watch?v=MvQQ0ZUisRI

https://www.youtube.com/watch?v=KJpfhNlXeu4

 Steps:

   1.  Select pieces of scrap wood for your glue-up.  These pieces can be different species of wood to add different colors and grains to the project, or they can be several pieces of the same species of wood.  If you are using all pieces of the same species, another option is to rotate every other piece in your glue-up to form an interesting edge-grain/end-grain pattern. 

    2.  Determine how you want to glue the boards together.  Be mindful of symmetry in the design, or you can go for a random asymmetrical look as well.

      3.  Face glue the boards together.  Make sure that you spread the glue across the entire face of the boards (1st pic below) and that you use many heavy duty clamps to pull the pieces together (2nd pic below).  You need to use more clamps than you would expect – this keeps small gaps from opening in the glue-up (3rd pic below).  See the pictures below - this is a glue-up of oak, cherry, and walnut.

     4.  Let the glue dry overnight.  Remove the excess glue with a scraper.

     5.  Flatten on edge of the glued-up blank (either on the jointer or with power sanders).  This will become the bottom of your box and will set on a table or other surface.

    6.  Draw your outside box design directly onto your glue-up blank OR, if you want to experiment with different box designs, practice on a piece of paper. When you have your design, cut it out and trace it onto the front face of your glued-up blank. 

IMPORTANT: YOUR DESIGN CAN NOT HAVE SHARP CURVES THAT ARE DIFFICULT FOR THE BAND SAW!  Because of how THICK the glue-up blank is, the band saw can’t make as sharp of a turn.  Please design with broad curves.

    7.  Cut the bandsaw box out on….THE BAND SAW!

     8.  Using power sanders, sand the outside on the bandsaw box.

    9.  Cut off the back of the box on the band saw.  The back is generally about ½” thick.  Store the back piece.

    10.  Design your drawer for your box.  YOUR DRAWER MUST BE ABLE TO BE MADE IN ONE CONTINUOUS CUT ON THE BAND SAW.  You cannot back up or make other cuts.  Just as before, the drawer should have no tight corners or 90° corners – it should be broad, smooth curves.  You will also have one entry cut for your drawer.

     11.  With the drawer cut out, glue and clamp your outer box back together.  Insert glue into the entry cut (from when you cut in for the drawer) and clamp.

    12.  and the outside of your drawer thoroughly

  13.  Cut off the front and back of your drawer.  This step is similar to cutting off the back of the box.  Generally, the front and back of the drawer are 3/8” – ½” thick.

     14.  Now, hollow out the inside of the drawer.  This cut-out determines the overall size (volume) of the drawer.

   15.  SAND EVERYTHING AT THIS POINT.  Pay close attention to sanding the inside of the drawer itself as well as the inside of the outer box.  You cannot sand these very well when the backs are glued back on.

     16.  Glue the back of the entire box back on – use 5-6 clamps to eliminate gaps (see pic below).

17.  Glue the front and back of the drawer back on – use 5-6 clamps to eliminate gaps (see pic below).

    18.  Sand the outside perimeter of the box and drawer so the backs and front are smooth and seamless

    19.  Design and cut out a drawer pull.  Glue to the front of your drawer.

     20.  Complete final sanding of all parts in preparation for finishing.    

     21.  Complete finishing of the project.  This may entail staining, tung oil, varnish, wax, or lacquer.

See pictures below for another example of a bandsaw box.  Notice the shape of the box, the drawer, and the drawer pull.