Introduction: Bandsaw Boxes Made Easy
Warning Bandsaw Box making can be addictive.
However 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
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)
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.
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 :)
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.
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)
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.
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.
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.
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
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.
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!
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)