How to Construct a Bandsaw Box

How to Make a Bandsaw Box

Bandsaw boxes are easy to make, but you need to follow a few rules of the road. It’s very important that you use the right blade, and that you make the cuts in the correct sequence. This story lays out the bandsaw project for you, start to finish. Click on the images to enlarge them for more detail.

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Use a good size chunk of wood for the box. In this article I’m using a 3” x 4” x 6” piece of spalted tamarind. I wouldn’t use anything less than 2” thick, 3” is better. Hardwoods and softwoods are both fair game. If you can’t find big blocks to work with (although a Google search for bowl blanks will help you there) there’s nothing wrong with gluing pieces up to make a block.

I do the bandsaw work with a 3/16” 10 tpi (teeth per inch) blade. With its fine tooth count you’ll need to take it easy on feeding the material. But you’ll be left with surfaces that require very little sanding. This is important for the fit of the drawer.

Shape the Bandsaw Box

How to Make a Bandsaw Box

Define the outside shape of your bandsaw box. This is completely subjective, and beauty is in the eye of the beholder. I prefer to use a flexible curve (see Sources) to create the shape.

How to Make a Bandsaw Box

Cut the outside of the box to shape. Take it easy on the bandsaw blade, using a slow but consistent feed rate. Listen to your saw, and slow down if it sounds like you’re over feeding. Try to make the cut in one fluid motion, without starting and stopping the feed. This will minimize bandsaw marks.

How to Make a Bandsaw Box

Notice that I cut feet on the bottom of the box. This isn’t a must, the bottom could remain flat, but I think it looks better with feet.

How to Make a Bandsaw Box

Set up a resaw fence and cut the back off the box, making it 1/4” thick.

How to Make a Bandsaw Box

Use the flexible curve to draw the drawer opening. I make the outside of the flexible curve even with the outside of the box, and then trace the inside edge.

How to Make a Bandsaw Box

Radius the inside corners using a washer. For a 3/16” blade a washer with a diameter of 1-1/4” creates an arc the blade can follow. Don’t leave any sharp corners in the drawer opening.

How to Make a Bandsaw Box

Cut the drawer opening. Notice that my entry cut, near my right hand, was made parallel to the grain of the blank. This makes for a better glue joint when you glue the box back together, long grain to long grain, and will also help make the glue seam more invisible. The chunk that comes out of the interior of the bandsaw box becomes your drawer.

Make the Drawer

How to Make a Bandsaw Box

Set up your resaw fence for a 1/4” cut and cut the front and back off the drawer piece. Notice the two lines I have on the top of the piece. This is to remind me to cut one slab from each of the two faces, not two slabs from one face.

How to Make a Bandsaw Box

Cut out the inside of the drawer. Use the flexible curve to define the shape, just like you did on the box. Except that in this case you need to create a U shape, open at the top of the drawer.

How to Make a Bandsaw Box

Bandsaw Box Sanding and Assembly

Glue the box together by working glue into the entry cut using a tooth pick. With the irregular shape of the box masking tape makes a great clamp.

How to Make a Bandsaw Box

Glue the back slab onto the drawer after sanding the bandsaw marks off the drawer interior (using a spindle sander) and from the inside faces of the back and front slabs (by hand). Once the glue on the back is dry, glue on the front.

How to Make a Bandsaw Box

Drill a 5/8” hole in the back. The hole provides finger access so you can push the drawer open.

Sand the interior of the bandsaw box using a spindle sander, and then glue on the back. I don’t sand the saw marks off the inside face of the back, since you really can’t see this surface. When the back is dry sand the box exterior.

When the drawer is dry sand the exterior surface to remove the bandsaw marks. Do as little sanding as possible. Part of the key to the completed box looking cool is having little more than the kerf of the bandsaw blade removed between the drawer and the box.

How to Make a Bandsaw Box

Apply a coat of finish, and your bandsaw box is complete.

Sources:

Flexible curve
#16M41
Woodcraft
woodcraft.com
(800) 225-1153

3/16” tpi bandsaw blade
pswood.com
(800) 939-4414

Discussion
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23 Responses to “How to Construct a Bandsaw Box”
  1. Neal Grossman

    Just before you showing how you used a washer for the radius there are duplicate pictures of the back being removed yet the text explains how to use the bendable curve.

    Reply
  2. Peter Johns

    What an outstanding presentation !! Am now motivated to give it a go. And this is the very reason I signed up with WGoA. Looking forward to more of the same eg fingerjointed boxes, fitting lids to boxes with quadrant hinges and with butt hinges etc, esp showing how to use a chisel to remove the timber for butt hinges

    Reply
  3. John Sackuvich

    I glue up a block of wood about 5 1/2″ deep I when cut a 1/4″ off the back. Next I cut out the drawer and take a 1/4″ off the back and 1/2″ off the front. After that I cut the drawer out ,sand the inside and glue the front and back the drawer back on. After sanding the inside of the box I then glue the back of the box back on and cut the outer profile. Do more sanding and apply the finish.

    Reply
  4. Keith Mowbray

    Nice item,very well detailed ,I will be trying this with some spalted sycamore.I think I have seen a suggestion that if you take the square back off the blade by carefully touching the back of the blade with oil stone,to ease tight corners.

    Reply
  5. Phillip Woodard

    Great explanation. You made the whole process very easy to understand and follow. Thank you.

    Reply
  6. Paul McDaniel

    Great vedio, I will try this as soon as my new blade gets here.

    You left the “10” out of the ” 3/16” tpi bandsaw blade” in the “SOURCES:” listing.

    Reply
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  7. fiberinspector

    I have made many, many, many bandsaw boxes, let me tell you they sell very well at craft shows.

    Reply
  8. Graham Neufeld

    Good presentation vary easy to follow discription . This is another good way to kill a couple of hrs in the shop & put all the left over end blocks to use .

    Reply
  9. Gary Pearce

    I watched the video on these band saw boxes and I had to try one. I made mine out of Cedar and it came out great. Now I’m going to do one out of Elm!

    Reply
  10. Virgil

    I have made many using Myrtle wood . Love the idea. But about other plans. How do I print just the plan an not anything else?

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      Hi, Virgil. Please contact us at 1-855-253-0822; our Customer Service Team would be happy to assist you.

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  11. Don Garrett

    I taught woodworking for over 20 years and this is one of the favorite projects of the students and me, had one that was about 12 ” high with a lid on top and a drawer in the bottom.
    we also turned out some fantastic table lamps, this was in Hawaii and the students did quite well in competition with them, lots of blue ribbons. Been retired quite a while now and I sure miss the kids.

    Reply
  12. Todd woodrum

    Great vid I’ve been making bsaw boxes for years but never like this. I’ve always wanted to but your vid was so easy. I made one today and plan on making tons more! Thanks so much!

    Reply
  13. Frank Blacker

    Just bought a Laguna 14″ bandsaw for making boxes. How tight of an inside radius can you make?

    Reply
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      Hi David. This issue has now been fixed. We are sorry for any inconvenience.
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