A band saw box can be used to store small items such as jewelry, coins or just about anything you can fit inside the drawers. This type of box is called a Band saw Box because you can make it using only one Saw, you guessed it, a Band Saw. You can let your imagination run wild and come up with a unique box. This box is 7" at its widest point, 8" Tall and 3 1/2" deep.
I sketched a rough drawing of this box several moths ago. My son and I cut the pieces of wood needed for the project and glued them up. I stored the glued up blank and pattern in my shop, with the plan to finish the project soon. Months later, I walked into my shop with the idea of working on a picture frame project. I quickly found that my table saw bearings were melted. I wasn't too happy about my table saw being broken. I needed to let some of my newly found stress out. I wanted a fun project that did not require a table saw. I remembered about the band saw pattern and blank I stored moths ago. I finalized the pattern and got to work. At the end of the day, I was really happy I created a beautiful box instead shutting down and being upset about a broken tool.
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Step 1: Tools Needed
* Band Saw
*Spindle Sander (sanding can be done by hand or hand sanders but a spindle sander speeds things up)
The internet has plenty of patterns to choose from but you can come up with your own. The only limitations are based on your saw and saw blade specs. I own a 9 in. band saw with a 3/16 by 10 Teeth Per Inch saw blade. This blade allows for a tight radius and could handle cutting this shape, check yours Saw and blade for specifications.
Step 2: Glue Up
My son Noah makes sure he is always present for this step, he enjoys getting messy. I placed newspaper on my work surface to help with the clean up. I used three pieces of scrap plywood and one Piece of curly cherry for initial glue up. My son spread a liberal amount of wood glue between the pieces. We clamped the four pieces of wood together and allowed for the glue to dry.
Step 3: Transfer the Pattern to Glued Up Blank
There are several ways you can transfer your pattern. You can use spray adhesive, or a glue stick to apply your pattern. This method usually leaves some of the paper behind, and you will have to remove later.
I prefer use carbon paper method. I simply place carbon paper over my blank, then my pattern. I use painter's tape to hold everything in place. Using a pencil, I trace the entire pattern onto the blank. When i'm positive the entire pattern has been transferred, I remove the carbon paper and pattern.
Step 4: Cut the Outer Shape
I started out by cutting the outer shape of the box, making sure not to get too close to the line. The tight radius and curves can be tricky to cut. I took my time and made relief cuts to make it a little easier.
Step 5: Cut the Drawers Out
I Started out by cutting the bottom drawer. I cut slow and steady making sure to keep the blade on the line.
Note : Do Not force it, allow the saw to do the work.
Once the first drawer was cut out, I TURNED THE SAW OFF and pulled the drawer out. If the drawer is binding, you can back off the same cut, but make sure the saw is off.
With the saw still off, I set my work piece up for the next drawer. I then cut the next drawer out. I repeated this process until I cut all the drawers out.
Step 6: Glue the Seams of the Box
Apply glue to the seams or cuts the were created as part of cutting out the drawers. Take your time and make sure everything lines up. Use several clamps and apply plenty of pressure to these joints. Glue squeeze out is a good sign you are applying enough pressure. Using a damp rag,clean up any glue squeeze out and allow for the glue to dry.
Step 7: Creating the Drawers
Note : Make sure to keep track of the drawer orientation and position in relation to the box. Start out by drawing a 1/4" line from the front and back of the drawer. This measurement doesn't have to be exact.
Cut out the front and back of the drawer and save those pieces.
Essentially you need to create a void, Draw the void you wish to create on the drawer and cut it out.
If you are planning on using flocking (a suede technique) you are ready to glue up. If you are going to use only a finish on the inside of the drawer, you need to sand at this time, since the drawer is still in pieces. This can be done at a later time but it will be a lot more difficult to do.
If you have kept track of all the pieces, gluing the drawers back up should go smoothly. Use wood glue and a couple of clamp and reassembly the drawer.
Step 8: Attach the Back of the Box
While the drawers are drying, Sand the inside of the box as well as rough sand the outside shape. Do not sand too much of the inside, since the more material you remove the bigger gap you will create.
Using a pencil, trace the outside shape of the box on to the back panel of the box. Cut out the shape on the band saw.
Apply glue and finally join the back of the box with several clamps.
Step 9: Making Drawer Pulls and Applying Finish
Making Drawer Pull
I used my drill press and a 3/8" plug cutter to cut the drawer pulls. You can use a hand drill if you do not have a drill press. I took the piece of wood to the band saw and cut the plugs out.
I didn't like the sharp edges of the drawer pulls so I decided I was going to round the edges over. To speed up the process, I chucked a dowel rod to my drill. I used a small amount of C A glue to temporarily attach the plug to the dowel. I engaged the drill and using a piece of sandpaper, I rounded the edges over. I snapped the plug off the dowel and repeated this step for the remaining drawer pulls.
After marking the location of the drawer pulls on the box, I used a 3/8" forstner bit and drilled about 1/16 of an inch on the drawers. I glued the drawer pulls and held them in place until the glue dried.
After a little bit of finish sanding with 150 grit, I applied 3 coats of general finishes' Arm-R-Seal. I sanded to 320 grit between coats.
Step 10: Flocking the Drawers
Flocking is the process of depositing many small fiber particles (called flock) onto a surface. It can also refer to the texture produced by the process.
In this case flocking consists of a black colored glue and black suede fibers.
I taped around the void of the drawers and brushed on a coat of glue. I placed the suede fibers in the applicator and applied the fibers.
This process gives a box drawer a clean and professional look. It also provides a soft and smooth surface that will ensure the items place inside will not be scratched.
Step 11: Free Pattern and Build Video
I have made this pattern available for free download. I would like for it to remain free and available to anyone that wishes to use it.
I have a you tube Channel and would appreciate it if you checked out my build video.
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