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For this project, we researched how to make bandsaw boxes and then physically made one. The steps below detail the process I went through to make it. All of the main cuts for the shape of the box were done with a bandsaw.
The Project
Wooden Engineering 16-17.pdfThe directions for making this project.
Design Proposal
Entries
These are the steps and things I did day-to-day.
Construction
Gathering Materials - Stacking and Gluing Wood:
In this step I gathered the wood I wanted to use, marked off sections to be cut, cut out said sections with the miter saw, and stacked and glued the pieces together.
The wood I used (ash on the right, walnut on the left).
An image of the pieces clamped together and gluing.
An image of the glued stack of wood.
Drawing Outline - Initial cuts:
In this step I drew my part onto paper which I then glued onto the stack of wood. This would allow for the following of a template. I then roughly cut out the main outline of the box and cut of the back 1/4 in so that when cutting the inside sections, the back of the box does not get ruined.
Drawing the outline.
Gluing outline to stack of wood.
Cutting main outline.
Cutting off back of the box.
Cutting the Inside Drawer Outline and Front and Back of Drawer:
In this step I cut into the middle of the box and cut out the outline of the drawer. On the right is the cut line visible. Not pictured is cutting off the back and front 1/4 in of the drawer like the one on the shell of the box.
Cutting the Inside of the Drawer - Sanding this Piece:
In this step I cut out the inside of the drawer. This is the area that will hold things. After cutting, I sanded the peice on the inside and outside to clean up the cuts and get ready for gluing and staining. I did this now as it would be much harder to do after gluing the front and back of the drawer on.
An image of the drawer cut done.
An image where I am sanding the drawer.
Gluing the Drawer Together - Filling Cut Line with Glue/Sawdust Mixture - Re-Sanding:
In this step I glue the front and back of the drawer back on (after sanding) so as to enclose the sides of the drawer and create a space to hold things. To fill in the visible gap where the pieces were joined, a mixture of sawdust and wood glue was used to attain similar, if not the same, coloring as the wood itself and merge the two pieces almost seemlessly. After this the drawer was re-sanded to get rid of the excess mixture and double check that the drawer was ready to have a finish applied. On the right is a picture of the front and back being glued on and the mixture (dark glue) being used to fill in the gaps (sanded later).
Sanding Shell - Gluing Shell - Filling Cut Line - Re-sanding:
In this step, I sanded the inside of the shell as it would be hard to get after gluing the back on. After this, I glued the cut into the inside of the box and then the back of the box back onto the shell. The first gluing made it so that the box could not flex open from the entry point. The second allowed for the box to have only one side the drawer could go in and a nice back. A similar mixture was used to fill in the gap created between the back piece and the shell itself. After all the gluing was done, the outside of the shell was sanded heavily to attain the shape desired.
An image of the sandpaper used to get a smooth feel after the main sanding with power tools.
An image of gluing the entry cut.
Creating the Handle:
After an attempt at using the bandsaw to cut out a handle and misaligning the sides on the sander, the Shark CNC machine in tandem with the program VCarve were use to make a new handle. I cut out a handle on this mahine which also included a lip for easier pulling out of the part.
20221213_103854.mp4Polyurethane:
After all parts were cut, sanded, and glued together, it was time to apply a finish. I chose polyurethane. To do complete this step I would coat the parts and then let them dry. To apply the second coat I lightly sanded all surfaces and then re-applied polyurethane. Two coats were one overall.
An image of the materials used to apply the polyurethane (rags, polyurethane, gloves)(Tung oil pictured as it was tested to see if that would be chosen over polyurethane).
An image of one layer of polyurethane on the drawer.
A comparison between one coat of polyurethane and none.
An image of two coats of polyurethane applied to the drawer.
An image of two coats of polyurethane applied to the shell and handle.
Final Product:
This is the final product. Two coats of polyurethane have been applied and everything is cleaned up. The handle is not currently fixed on as the glue did not stick after applying polyurethane to all of the parts. This will be fixed later with a better glue setup or screws.
The box closed.
A top view of the box with the drawer open.
A side view of the drawer open.
The box closed and with the handle held roughly in the right place.
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