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.