Band Saw Box
- Safety glasses or goggles should be worn whenever power
tools are in use and when chiseling, sanding, scraping or hammering overhead.
This is very important for anyone wearing contact lenses.
- Wear ear protectors when using noisy power tools. Some
tools operate at noise levels that damage hearing.
- Be careful of loose hair and clothing so that it does
not get caught in tools; roll your sleeves up and remove jewelry.
- The proper respirator or face mask should be worn when
sanding, sawing or using substances with toxic fumes.
- Keep blades sharp. A dull blade requires excessive
force and can slip which causes accidents.
- Always use the right tool for the job.
- Repair or discard tools with cracks in the wooden
handles or chips in the metal parts.
- Don't drill, shape or saw anything that isn't firmly
- Oily rags are spontaneously combustible, so take care
when you store and discard them.
- Don't abuse your tools.
- Keep a First Aid Kit on hand.
- Do not work with tools when you are tired. That's when
most accidents occur.
- Read the owner's manual for all tools and understand
their proper usage.
- Keep tools out of the reach of small children.
- Unplug all power tools when changing settings or parts.
KNOW WHERE YOUR HANDS ARE AT ALL TIMES!
The single most common mistake in any do it yourself
project is the failure to read and follow the manufacturer's instructions for
any tool or material being used. Other common mistakes include taking the safety
measures that are laid out for a project for granted, and poor project planning.
Here is a list of hints to successfully complete this project and to do it
- Follow the "Golden Rule" of measuring: "Measure twice,
- Provide yourself plenty of time for each step.
- Understand your plan. (if you have questions, review
that part of the videotape).
- When finishing the wood, keep dust and dirt away from
- Follow the application instructions for your choice of
- Allow an extra ¼" to " inch when cutting the stock.
- Experiment with scrap wood before you work on the real
piece. This will help with finishing touches.
Before you begin your project, you will want to become
familiar with the woodworking terms shown below.
- Miter Cut - Angle cut across the width or
thickness of the board
- Rabbet - L-shaped cut
- Dado - Channel cut across the board, into which
a second piece of wood is fined
- Kerf - Width of the blade
- Countersink - To set a screw head at or below
- Dowel - Wooden pin used to provide strength and
- Chamfer - Corner of a board beveled at a 45
- Laminate - Composed of firmly united layers of
The two basic categories of wood used most often in wood
working projects are hardwood and softwood. Hardwood is more durable and less
prone to dents and scratches. It is also more expensive but will finish to a
better advantage. Soft woods, like pine, are more prone to dents and scratches
and do not have the durability of hardwood. Softwoods are much less expensive
and easier to find.
Ask your lumber supplier to show you "Class 1 " or "Select
Grade" lumber. Make sure it is properly dried, straight, and free of knots and
defects. (It may be impossible to be completely free of defects but be sure you
understand how to cut around these.)
Ask your Lumber supplier for assistance when purchasing
your wood. Similar to laying a pattern out on a piece of cloth, often you can
cut several different pieces of the same thickness of wood out of a single
piece. It is a good idea to add up the total number of board feet, being careful
to make sure you group short pieces in a board with long pieces to minimize
This project could be built out of scrap wood already in
your workshop. If you choose to use new stock from the lumber yard, both
hardwoods and softwood are good choices.
Note: Developing a good relationship with Your lumber
suppliers is important. They can help guide you in making material selections as
well as making special orders for a type of wood you may desire for a project.
Now that you have reviewed safety hints, learned the
mistakes to avoid, reviewed the basic components and gathered your tools and
materials for your projects - you are ready to BEGIN!
Steps to Follow:
For this project you can use scrap pieces of wood from
other projects or a solid block of wood to create a beautiful box. The steps to
follow for this project are:
- Laminate the pieces of wood (if not using a solid
- Cut the block to size.
- Make the drawers.
- Finish sand the drawers and carcass.
the Scrap Pieces of Wood
- Stack scrap wood of approximate width and length
together for a stack that can be cut by your band saw blade.
- Use wood glue on the inside pieces of the stack and
clamp together and set over night to dry. Alternating the grains is a nice
touch depending on the wood scraps that you are using.
Cutting the Sides
(A & B)
- Using a ¼" width band saw blade cut the block to size.
A ¼" blade will be used for all the following cuts because it will provide a
tighter fit for the drawers and a neater cut.
- Mark the sides of the box, a "V" will do so that later
when you glue the box you know which side belongs where.
- Using the band saw cut the sides off being careful to
make the cuts straight and accurate for later assembling of the box. The tape
makes this cut at ½" into the solid wood.
Making the Drawers
- On the center block (C) mark the interior of the box
for your drawer. Make the corners rounded so that the band saw will not bind
when making the cut.
- Cut out the drawer (H) making sure to go slowly and
stay on the scrap side of the mark.
- Cut off the sides of the drawers (E&F) being careful to
mark their proper location for gluing later.
- Cut the interior of the drawer out, again being careful
to round the turns so that the band saw does not bind.
- Sand lightly all the pieces before gluing on the sides.
- F. Glue the sides on the carcass and the drawers. Use
clamps to hold tight till the glue dries, over night is suggested.
Finish Sanding the
Drawers and Carcass
- Using a belt sander finish sand the carcass. This can
be used to round the edges as well as smooth the glue joints on the carcass.
- The belt sander and fine sand paper can finish the
drawer. Make sure that as you sand, check the drawer often for smooth opening