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Bandsaw Boxes Made Easy

by Wood Chuck on August 24, 2010

Table of Contents

Bandsaw Boxes Made Easy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Intro: Bandsaw Boxes Made Easy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 1: Design Your Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 2: Prepare your blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 3: Blank Clean-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 4: .................................................................................................................. 3

Step 5: Sand Your Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Step 6: Slice off the back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Step 7: Cut Your Drawers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 8: Cutting the Drawer Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Step 9: Closing The Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Step 10: Sand Main Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 11: Sand Your Drawers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 12: Preparing Your Drawers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 13: Design your Drawer Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Step 14: Cut the Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Step 15: Sand Drawer Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Step 16: Re-Assemble Your Drawers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Step 17: Attach the Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Step 18: Make Your Drawer Pulls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Step 19: Attach Your Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Step 20: Apply Your Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

http://www.instructables.com/id/Bandsaw-Boxes-Made-Easy/
Intro: Bandsaw Boxes Made Easy
Warning Bandsaw Box making can be addictive.

H owever they are easy to create and make great gifts for storing little trinkets. Have Fun!

I want to thank Steve Ramsey at WoodworkingForMereMortals.com for his tutorial video that got me started in the box making world

Image Notes
1. My first three attempts

Step 1: Design Your Creation

Design your creation. You are only limited by your imagination. Or search the web for ideas. The following box is a facsimile of a picture I found created by " Lois Keener
Ventura"

Lois Keener Ventura wrote a book on making bandsaw boxes.

This design I drew up in Sketchup (free version)

Image Notes
1. I've found the design is only a guideline and usually chnages during the process

http://www.instructables.com/id/Bandsaw-Boxes-Made-Easy/
Step 2: Prepare your blank
Glue up a block to fit you design – unless you keep 12/4 material around!
On this particular box I used a piece of 8/4 Walnut for the core and 2 pieces of Lace Wood for the front and back. The total block measured 3 x 6 x 11

Step 3: Blank Clean-Up

This is not a required step, I just like to have the block squared up and clean on all sides before I head to the bandsaw.

Step 4:
Roughly cut out your template and attach it to the blank with spray adhesive. Be sure to leave enough room to sand to your line.

At this point you are only cutting the outside of your design.

Keep in mind the smallest radius you can cut is determined by the size of your bandsaw blade. I used a 3/16 or 1/4" blade for the boxes I've made so far.

NOTE: if you fail to follow your line don't worry, just consider it a design change :)

http://www.instructables.com/id/Bandsaw-Boxes-Made-Easy/
 Image Notes
1. Try to cut in one fluid motion, it makes for less sanding.

Step 5: Sand Your Creation

It easier to sand all of the curves now before you proceed. That way the back will be identical to the main body.

NOTE: I usually make my boxes around 3" thick so they will fit on my spindle sander!

Step 6: Slice off the back

Now slice off the back of your box. Mine are around 1/4" but that's your decision.

http://www.instructables.com/id/Bandsaw-Boxes-Made-Easy/
Step 7: Cut Your Drawers
Decide on an entrance point and cut out each drawer (In one motion if possible.)

Or if you come to a sharp point, stop your saw and back out of the cut

This box is a little different. there will be 2 entrance points. 1 will left open with the drawer exposed and the other will be closed. (see next photo)

Image Notes
1. There is going to be 2 entrance points on this box. One will be left open and the other will be glued closed.

http://www.instructables.com/id/Bandsaw-Boxes-Made-Easy/
Step 8: Cutting the Drawer Openings
See how the middle drawer is cut out after the lower drawer is cut out, by joining the two openings with a single kerf.

Step 9: Closing The Gap

Here I'm gluing my lower entrance point back together.

Depending on your design it is sometimes quite a challenge to place clamps.

http://www.instructables.com/id/Bandsaw-Boxes-Made-Easy/
Step 10: Sand Main Body
Sand all of the inside compartments where the drawers will go.

Step 11: Sand Your Drawers

While your glue is drying you can sand the outside of your drawer body

Step 12: Preparing Your Drawers

Now slice a front and back off your drawer bodies. Your choice for thickness

NOTE: You might want to mark your pieces in some way so you don't get the parts reversed. This will make sure the glue up goes smoother.

http://www.instructables.com/id/Bandsaw-Boxes-Made-Easy/
Step 13: Design your Drawer Compartment
Mark your drawer bodies with a shape that will become the inside of your drawer.

Don't make the corners to sharp, You still want to sand the inside.

http://www.instructables.com/id/Bandsaw-Boxes-Made-Easy/
Step 14: Cut the Drawer
Follow your pattern (roughly) and remove the drawer cavities

Step 15: Sand Drawer Curves

Before drawer assembly sand the inside of your drawers

http://www.instructables.com/id/Bandsaw-Boxes-Made-Easy/
Step 16: Re-Assemble Your Drawers
Carefull line-up the front and back pieces of your drawers and glue them back together.

This is when you will be glad you marked your components.

http://www.instructables.com/id/Bandsaw-Boxes-Made-Easy/
Step 17: Attach the Rear Panel
The rear panel of the main body can be attached, (actually it can be attached anytime after you glue your entrance point closed)

There will likely be a small amount of sanding along your glue line when it dries and near the entrance cut.

Step 18: Make Your Drawer Pulls

Design and cut out your drawer pulls (if reqyuired)

These are very small pieces - use extreme caution if you use a bandsaw to cut these out.

I chose ebony pulls for this box just to accent the Lace Wood

Step 19: Attach Your Handles

Attach your handles and your done!

http://www.instructables.com/id/Bandsaw-Boxes-Made-Easy/
Step 20: Apply Your Finish
Finish with your favourite finish and show it off.

I hope you give these boxes a try, they are great fun to make and will make wonderful handcrafted gifts

Depending on the complexity of your design the whole project will only take 4 -5 hours. (Not counting waiting on glue to dry)

Enjoy
Bruce
(Wood Chuck)

http://www.instructables.com/id/Bandsaw-Boxes-Made-Easy/
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Comments
31 comments Add Comment

intdes says: Mar 7, 2011. 2:04 PM REPLY

interior design nyc

terbo3 says: Jan 18, 2011. 7:10 AM REPLY

Nice looking box that you made there! Band saw boxes always make me think of Alice in Wonderland... You've inspired me to give one a try; I've always
been a little wary of my bandsaw abilities, so I tend to stick to mitered jewelry boxes and the table saw.

BTW, if you're looking for nice, figured woods for smaller projects like this, you should check out Horizon Wood Product's online specialty shop. It's got a
pretty slick setup with zoomable photos and whatnot!.

http://www.horizonevolutions.com/eshop/

ebergh says: Nov 29, 2010. 11:10 PM REPLY

Nice use of photos... clearly shows the steps! Bandsaw boxes are an easy project and a good way to use up shorts by laminating them up to make the box
blanks.

My students usually finished of the interiors of the drawers by brushing them with a coat of enamel paint and then blowing in a puff of rayon flock of a
matching color. It gives them the look of being lined in felt and hides any minor sanding faults.

Very creative shapes in your examples!

Wood Chuck says: Nov 30, 2010. 3:59 AM REPLY

Thanks ebergh, those boxes were my first three I made. I have since started flocking the insides, even the inside of the opening which takes up a lot of
the bandsaw cut lines and the drawers slide very nicely.

http://www.instructables.com/id/Bandsaw-Boxes-Made-Easy/
 dirkbo7 says: Oct 20, 2010. 2:45 PM REPLY
I was wondering what type of bandsaw you use? I have finally received permission to get one from the boss and have been doing my research. Any input
would be great.

Wood Chuck says: Oct 20, 2010. 6:20 PM REPLY

I use a 14" Delta model # 28-206. When I was researching bandsaws I liked the blade support system both above and below the table. I have been
pleased with the peformance of the Delta. Hope that helps. Bruce

speedyspy2 says: Oct 14, 2010. 8:06 PM REPLY

Nice instructible. i saw on of these in a store that sold homemade wood projects and made onee myself in carpentry class. mine was half of a tree stump
(semicircle flat side down curved side made of bark) and gave it to my grandma for mothersday. i plan on making one like yours soon

Wood Chuck says: Oct 15, 2010. 4:20 AM REPLY

Thanks for the comments - have fun

sawtooth1953 says: Sep 26, 2010. 8:12 AM REPLY

Nice job. I think it should be mentioned that this size box cannot be made on a benchtop sized band saw... those typically have a max. height capacity in the
neighborhood of 3 1/2". This project was cut using a full sized band saw whose capacity is likely closer to 7". The step where the back is cut off is the limiting
step... if the box on its side is taller than your saw's max. height capacity, then you can't cut off the back. Benchtop band saws can certainly make boxes with
this method, but the design has to take that dimension into account... same with scroll saws, whose max. height capacity is typically around 2", give or take a
little depending on the model.

Wood Chuck says: Sep 26, 2010. 9:21 AM REPLY

Thanks for you input sawtooth1953, it's amazing what you have to consider when writing one of these instructables. Cheers

zippydaspinhead says: Oct 1, 2010. 10:37 PM REPLY

While sawtooth is correct I think it prudent to say that you don't NEED to use a band saw to cut off the back. Other tools may be used. However a full
size band saw would probably make the BEST cut.

Wood Chuck says: Oct 2, 2010. 5:41 AM REPLY

Actually all you really need for capacity for this particular box is about 3", you just lay it down to cut the back off

corsi says: Sep 1, 2010. 10:54 PM REPLY

i was about to say.... these pictures look really familiar. but then i saw that it was in fact Bruce aka. wood chuck. my favorite youtube channel did a piece on
you and you bandsaw boxes. thanx

Wood Chuck says: Sep 2, 2010. 4:11 AM REPLY

Corsi; Where might that be? You must be refering to the Woodworking for mere mortals site. Steve was the one that suggested entering this instructable.

corsi says: Sep 11, 2010. 8:48 PM REPLY

It was infact the very one. Have watched all of his videos. I have made several bandsaw boxes with the help of this instructable.

moonshinebluebird says: Sep 2, 2010. 11:31 AM REPLY

wow, thanks so much Wood Chuck. I'm going to give this a try, the instructable is great!

Wood Chuck says: Sep 2, 2010. 12:12 PM REPLY

Your welcome - have fun

quadracer says: Aug 29, 2010. 4:05 PM REPLY

Very nice work! Im going to have to try this as my next wood working project, Thank you. Now only if I had one of those sanders. And the saying goes, you
can NEVER have too many clamps.

littlepetry says: Aug 27, 2010. 6:30 PM REPLY

Very nice. Inspiring. When ever I try to make sharp turns on my bandsaw like you're doing, my blade breaks. What am I doing wrong? Any turns that I make
on my band saw has to be very slight. Any Ideas?

http://www.instructables.com/id/Bandsaw-Boxes-Made-Easy/
 Wood Chuck says: Aug 28, 2010. 4:07 AM REPLY
You shouldn't be breaking blades, unless you are trying to make turns that are too sharp for the size of your blade or your saw needs a basic setup. I've
included a link to Marc Spagnolos site (aka The Wood Whisperer) He goes over a basic tune-up, in particular blade tension. I hope this helps you out.
Bruce http://thewoodwhisperer.com/bandsaw-setup-tuneup/

littlepetry says: Aug 29, 2010. 2:25 PM REPLY

Thanks!

boognishmofo says: Aug 28, 2010. 1:13 PM REPLY

I wonder how well this would work on a scroll saw? wish I had a band saw. nice work.

Wood Chuck says: Aug 28, 2010. 2:20 PM REPLY

boognishmofo: there is no reason why a scroll saw wouldn't work. I know my scroll saw is very small and the stroke distance is too short - unless your
going to make very small boxes. WC

marjorieallea says: Aug 27, 2010. 11:39 AM REPLY

All three of your boxes are beautiful!

Isamuk says: Aug 26, 2010. 5:47 PM REPLY

Absolutly amazing you have changed the game for woodworkers

Wood Chuck says: Aug 27, 2010. 3:52 AM REPLY

Thanks Igor

canida says: Aug 26, 2010. 11:00 AM REPLY

Beautiful work!

Wood Chuck says: Aug 26, 2010. 10:44 AM REPLY

Thanks everyone for the encouargement and kind words. They really are fun to make.

jeff-o says: Aug 26, 2010. 10:36 AM REPLY

Nice. I've been meaning to make a bandsaw box for a while but never got around to it. Your instructable is nice and clear, well done!

mikeasaurus says: Aug 26, 2010. 8:35 AM REPLY

cool, the results look great!

valhallas_end says: Aug 25, 2010. 8:03 PM REPLY

Very nice. I've seen these in wood-specialty stores for rather high prices...I never thought of making my own this way though. Well detailed, and beautiful
final product!

http://www.instructables.com/id/Bandsaw-Boxes-Made-Easy/