Saturday, March 28, 2015

Make a Bandsaw Box without a Bandsaw - An Un-Bandsaw Box

I like the look of bandsaw boxes, but I didn't have a bandsaw at the time. 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.

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.

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.

I traced and roughed cut the next ring and 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.

For the lid insert, 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 and taped the lid to the rings. I shaped the lid on the router table with the flush trim bit.

For the bottom, I traced the outside shape on another piece of polar and rough cut it with the jigsaw.

I glued it to the rings and  finished the bottom with the flush trim bit.

I rounded the top and bottom with a rounding bit and 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.

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.

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