Introduction: Make a Bandsaw Box Without a Bandsaw - an Unbandsaw Box
I like the look of bandsaw boxes, but I didn't have a bandsaw at the time I made this. I wanted to see if I could make something that emulated a bandsaw box anyway. It's not emulating the more familiar drawer style box, but the kind with the removable lid. All you absolutely need is a jigsaw, drill, router table with flush trim bit, and some sandpaper.
Step 1: Make a Template
- I sketched an irregular shape on some 3/4 inch MDF.
- I rough cut the outside of the shape with my jigsaw.
- I drilled out the center and cut out the inside with the jigsaw.
- I used a sanding drum on my drill press and a disk sander to do final shaping of the template.
Step 2: Make the First "ring"
- I traced the template shape on a 1/2 inch piece of poplar.
- I cut out the outside and inside of the poplar as with the template, leaving about 1/8 inch or less on the waste side of the line.
- I applied double sided tape to the rough shaped poplar and attached the template to it.
- I used a flush trim bit on the router table and used it to transfer the shape of the template to the poplar.
Step 3: Make the Other Rings
- I traced and roughed cut the next ring.
- I glued the rough cut ring to the finished ring.
- I also tacked it on with a few brad nails.
- I shaped the rough ring on the router using the previous finished ring as the template.
- I repeated for all the rings, not using the brad nails on the top ring as it would show.
- I used some sandpaper taped to a dowel to smooth the inside and outside of the rings, while wished I had a spindle sander.
Step 4: Make the Top
- I sketched the inside shape of the box on some 1/4 plywood for the lid insert.
- I cut it out with the jigsaw.
- I finished shaping the insert with the sanding drum and belt sander.
- I glued the insert to another 1/2 inch piece of poplar.
- I rough cut the outside shape.
- I taped the lid to the rings.
- I shaped the lid on the router table with the flush trim bit.
Step 5: Make the Bottom
- I traced the outside shape on another piece of polar.
- I rough cut it with the jigsaw.
- I glued it to the rings.
- I finished the bottom with the flush trim bit.
Step 6: Final Shape and Finishing
- I rounded the top and bottom with a rounding bit.
- I used a chamfer bit in the underside of the lid and the top of the box.
- I finished the box with a few coats of Danish oil.
Step 7: Complete
Now you have a box that looks like it was made on a bandsaw. Would it be easier to make with a bandsaw? Probably, but I didn't have one at the time.