The Basics of Bandsaw Boxes

In this Instructable, I will step you through the basics of bandsaw box making.

A block of wood. The best is something that won't split easily. I typically use pine.

A bandsaw. (Of course. Wouldn't be much of a bandsaw box without it)

A sander. A good belt sander or palm sander will work good for the outside. Hand sandpaper or a drum sander works best for the inside

Wood glue

Lacquer of your choosing.

Optional:

1. Dremel tool or equivalent.
2. A wood carving and sanding bit for said Dremel tool
3. A blowtorch

It probably goes without saying, but bandsaws are sharp, blowtorches are hot, and sanders sand. Please don't hurt yourself but if you do, don't say I didn't warn you!

Take your block of wood and use the bandsaw to make all the edges squared. This makes the rest of the process much easier. Then cut out the shape of the outside of your box.

Next cut the top off your piece of wood. This will become the lid. I typically keep it about 1/2 inch thick. Side note: I am using a square box for this demonstration but all the same principals apply to any other shape.

Same as above. But this time cut the bottom off the piece of wood. This will be the base of the box

Next, you want to cut the sides. With a square box, you cut in from opposite corners as shown. With a circular box, you only have to cut in from one side.

Now take the middle chunk, (the piece that was left after cutting the sides) and cut a piece off the top. This will be the plug (the bit that stops the lid from sliding off).

If you want to sand the inside of box, now would be a good time to do that. Especially if you are making a rectangular box. When that is done, glue the two sides of the box together, then glue the sides to the base. You want to try your best to line up the grain. Once the glue is dry, sand the box smooth.

Once the glue on the box is dry, use it to center the plug so that the outside of the lid lines up with the outside of the box. Glue the plug to the lid. Then sand it when the glue is dry.

Optional: You can take a Dremel tool or other tool like this and carve patterns into the outside of the box. Then take a blowtorch and carefully char just the raised portions of your carvings.

Lacquer it, stain it, or whatever you heart desires. And you're done!