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Make a Box by Moy perez woodshop on March 19, 2016

Table of Contents

Make a bandsaw Box ...... 1

Intro: Make a bandsaw Box ...... 2

Step 1: Tools Needed ...... 2

Step 2: Glue Up ...... 4

Step 3: Transfer The Pattern To Glued Up Blank ...... 5

Step 4: Cut The Outer Shape ...... 6

Step 5: Cut The Drawers Out ...... 6

Step 6: Glue The Seams of the box ...... 7

Step 7: Creating The Drawers ...... 7

Step 8: Attach The Back Of The Box ...... 8

Step 9: Making Drawer pulls and Applying Finish ...... 9

Step 10: Flocking the Drawers ...... 10

Step 11: Free Pattern and Build video ...... 10

Related Instructables ...... 11

Advertisements ...... 11

Comments ...... 11

http://www.instructables.com/id/Make-a-Bandsaw-Box/ Author:Moy perez woodshop I'm just a guy that likes to make things.

Intro: Make a bandsaw Box A band 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.

Step 1: Tools Needed * Band Saw

*Spindle Sander (sanding can be done by hand or hand sanders but a spindle sander speeds things up)

*Clamps

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.

http://www.instructables.com/id/Make-a-Bandsaw-Box/ http://www.instructables.com/id/Make-a-Bandsaw-Box/ Step 2: Glue Up My son Noah makes sure he is always present for this step, he loved getting messy. I placed newspaper on my work surface to help with the clean up. I used three pieces of scrap and one Piece of curly cherry for initial glue up. My son spread a liberal amount of glue between the pieces. We clamped the four pieces of wood together and allowed for the glue to dry.

http://www.instructables.com/id/Make-a-Bandsaw-Box/ 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 it 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.

http://www.instructables.com/id/Make-a-Bandsaw-Box/ 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 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 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.

http://www.instructables.com/id/Make-a-Bandsaw-Box/ 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 the glue 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 created 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 and a couple of and reassembly the drawer.

http://www.instructables.com/id/Make-a-Bandsaw-Box/ Step 8: Attach The Back Of The Box While the drawer 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 of the box. Cut out the shape on the band saw.

Apply glue and finally join the back of the box with several clamps.

http://www.instructables.com/id/Make-a-Bandsaw-Box/ Step 9: Making Drawer pulls and Applying Finish Making Drawer Pull

I used my press 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 to 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 , I rounded the edges. 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 in place 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

http://www.instructables.com/id/Make-a-Bandsaw-Box/ 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 give a box drawer a clean and professional look. It also provide 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 a you tube Channel and would appreciate it if you checked out my build video.

http://www.instructables.com/id/Make-a-Bandsaw-Box/ Related Instructables

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