Every woodshop has its share of small pine scraps laying around and mine is no exception. What better way to experiment with a new technique? I present to you, my first bandsaw box!
The bandsaw box has always intrigued me, yet I never made one until now. I kept the project simple and focused on the fundamentals. The finished product can look more complex than the actual construction.
Those scraps of pine
I knew they were destined for something greater than the fire pit. I gathered enough pine scraps to equal the volume of the box.
Chop ’em up
On the miter saw, I sized the pieces to an a similar length, what would be the approximate width of the box. A high degree of accuracy was not needed for this step.
Glue ’em up
With a brush, the glue is spread evenly between the boards. They were never coming apart!
You got me under pressure!
Four spring clamps apply enough pressure. And with this step, I called it quits for the day and let the glue dry.
Lay it out
This is where things get interesting. Any shape can be made. I’ve seen some very complex shapes used for bandsaw boxes. Perhaps I was a fuddy-duddy; I chose a semicircle and sketched it with a compass.
Cutting out the box
So, this is where it gets its name. The bandsaw is used to cut out the box shape.
Secret revealed
The back is cut off in preparation of hollowing the box. I used a fence to slide the work piece and ensure a straight cut.
Fun Fact: For whatever reason, I imagined slicing provolone cheese.
Layout the drawer
Again, any shape can be used. This day, I had circles on my mind.
Maybe next time, I’ll do something wild!
Multitasking
Well, multitasking is not always overrated. In this step, the box is hallowed and the drawer is cut out.
The blade actually cuts through the outer box and will be glued back together later on.
Slicing provolone cheese again
It must have been lunchtime; I’m still thinking of cheese!
Now, I’m removing the front and back of the drawer before hollowing out the inside.
It got away!
Although the bandsaw is a relatively safe tool, danger is still present. The front of the work piece was pulled down by the blade, causing it to rotate. The work piece ricocheted off of the table and struck the red blade guard.
Removing the inside of the drawer
So, this is why it’s called a bandsaw box! How will I remove the material for the drawer? With the bandsaw!
All the parts
Clockwise from top left: box, drawer front and back, box back, and drawer.
There are so many ways these parts could have been machined. This method, however, must be one of the simplest.
Shaping and sanding the drawer
The one inch belt sander comes in handy for detailed work. The inside of the drawer is shaped and sanded with this handy tool. The radius will be sanded with a drum and by hand.
Drawer assembly
With some wood glue, the drawer is assembled.
Not shown: I decided to glue on a decorative plug to use as a knob.
Shaping and sanding the box
A drum sander attached to the drill press makes quick work of shaping and sanding the inside of the box.
Care must be given not to sand too aggressively. If too much material is removed, the drawer will have a sloppy fit.
The spring clamp gang
Spring clamps apply plenty of force for the glue ups in this project. Both drawer and box are assembled.
Shaping the drawer and box
I’m using the belt sander to shape and remove tooling marks from the drawer and box.
I decided not to attempt to remove the damage from the drawer mishap earlier. Doing so would increase the gap between the drawer and box.
A nontraditional finish
I decided to finish the box in a nontraditional way. Using blue food coloring and spray lacquer, I created an interesting color and nice shine.
My first bandsaw box
I’m glad that I finally tackled this project. I’ve seen bandsaw boxes at art shows, woodworking magazines, and all over the internet. Now, I can find one in my living room! It was an easy project, but one that was fun to build!
