Bandsaw boxes in 10 easy steps

Very simple if you have a bandsaw:
1) Glue up some layers of plywood, sandwiched between two pieces of oak
2) Print out a cartoon shaped heart from the internet and stick to the top of the block. Add a stand to the piece of paper.
3) Follow the outline with the bandsaw, trying not to cut off your fingers with the saw. Doing “relief” cuts at the top and where the stand meets the body of the box makes means you don’t have to back out the blade.
4) Mark on the paper to show where you want to cut the drawer about 6mm from the edge of the outside. Cut out the shape, coming in at the bottom and following the curve round to the top central point, then back the blade out, and repeat the cut on the other side to create the drawer.
5) Cut off the front and back of the draw.
6) Carve out the inside of the draw with the bandsaw, in this case with two simple straight cuts.
7) Sand the drawer front and back smooth so you get a nice tight joint. Sand the inside and out of the box. The inside curves are easy with a spindle sander. The outside curves are best done with a flat sander, like my random orbit sander. Round off the corners of the front whilst you’re at it.
8) Glue the front and back of the drawers on, and the top of the heart shape back onto the base where the entry points for the bandsaw was created
9) Finally place the box on a sheet of sandpaper on a flat surface and sand the bottom of the box until it stops tipping. I’ve never made anything like this that didn’t tip when placed on a flat surface.
10) 5 coats of shellac with a light sanding with some 220 grit sand paper after the 1st coat, 3rd and 4th coat, leaving a minimum of an hour between the coats for the shellac to dry. In the cold weather we’ve been having I’ve been leaving it on front of a heater on a low setting to make sure the alcohol solvant flashes off properly.

Not including the glue up and shellac drying times, probably took me a couple of hours or so to do. The sanding takes the most time because you have to start with the 80 grit sandpaper, then the 120 grit and finish with the 220.
Of course without a bandsaw, it’s rather more difficult but could be done with a coping saw if you really want to spend hours cutting it by hand.



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