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Making a bandsaw box from scraps of wood

19th August 2015 By Gidon 6 Comments

Completed bandsaw box

I decided to make a bandsaw box for my daughter from scraps of wood leftover from other projects. This is a great little project if you have a bandsaw and something I’ve never tried before. If you don’t own a bandsaw, then I hope you still may find this of interest.

The attraction of a bandsaw box is that they can be made any shape or size you want, from scraps of wood. And they can be done completely freehand. You need a hunk of wood around 3 or 4 inches thick and ideally a narrow blade on your bandsaw. I’ve used a 1/8″ blade from Tuffsaws for the tighter curves and a 1/2″ blade for everything else.

There’s a nice mystery to a completed bandsaw box that will be revealed in this post. At first glance it’s hard to conceive how the box is constructed.

First off, you’ll need a thick piece of wood which can be made up by laminating thinner pieces together. I’ve sandwiched a few cut offs of birch plywood in between some thin scraps of Ash. Dimensions don’t matter. Clamp them all together with glue and let it dry.

Wood sandwich of plywood and Ash
Wood sandwich of plywood and Ash

Cut out the shape of the box. This can be whatever you like – I’ve gone for a basic curve printed off the computer and stuck to my block of wood with spray adhesive.

Cut outside of box
Cut outside of box

Sand this smooth and slice off 1/4″ off the back of the box.

Slice off back of box
Slice off back of box

Then layout the drawer of the box which we’ll cut out next. Try and enter the cut along the grain of the wood. We’ll be gluing this shut and this should be invisible to the untrained eye when the box is finished.

Cut out inside of box
Cut out inside of box

Slice off 1/4″ off the front and back of this inside of the box. Make sure everything is labelled. Now we need to cut out the drawer itself. Layout a u-shaped design of your choice and cut this out.

Next we need to sand all the curved surfaces. This is a fairly tedious job and if you’re just making this for fun you can stop when you like. If you go too far the drawer will be a little sloppy. I’ve used a Triton oscillating spindle sander which makes quick work of it. But so long as my daughter’s not reading this – I left some little seen surfaces fairly rough!

Using oscillating bobbin sander
Using oscillating bobbin sander

Now all we need to do is glue it all together.

Glue it all together
Glue it all together

Rather than a drawer pull, drill a hole in the back to push the drawer open.

Drilling hole in back to open drawer
Drilling hole in back to open drawer

More sanding and it’s ready for finish.

More sanding and ready for finish
More sanding and ready for finish

I didn’t like the look of the curved plywood edge so masked the Ash edges and faces with blue painter’s tape and painted it with a can of black spray paint from Lidl. The Ash had two coats of clear lacquer.

Masking reading for black lacquer
Masking reading for black lacquer

And here’s my daughter – I think she’s happy with it!

My daughter with finished box
My daughter with finished box

 

 

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Filed Under: Woodworking

Comments

  1. Ronnie O. Lambert says

    14th November 2015 at 2:20 am

    you are a handsome father. and your daughter very beautiful too, I really like to do something with my bandsaw. but i have no idea. I’m a poor father.thank you for this.

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  2. Barber H says

    1st February 2016 at 12:59 pm

    Great item. Thank you for sharing these steps, it would save my time learning how to make it. Your daughter looks really pretty and happy.

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  3. Steav Smith says

    30th April 2018 at 4:19 pm

    This is a great box you made there. Thanks for sharing the process.

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  5. Mathew says

    6th August 2019 at 3:39 pm

    Such an informative article. Now I’m trying to making a bandsaw box from scraps of wood according to your article. Hope I successfully made it.

    Thanks for your amazing article.

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  6. Sam Maxi says

    30th October 2019 at 4:18 pm

    I read your article and got some good ideas about making a bandsaw. As a beginner, this tutorial helps me to make a bandsaw box from scraps of wood. Really its a cool article about bandsaw and your writing is awesome.

    Thank you! Keep sharing.

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Gidon’s obsession with technology began at an early age with a BBC B Micro computer. After working for 12 years at British Telecom travelling around the world as a technology researcher he opened a technology retail store in Tavistock in Devon, selling the latest tech and offering IT services to residential and business customers. Read More…

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