Make a nice little jewelry or knick-knack box from a block of wood and your band saw. You can cut it out in minutes and finish it in an hour.
By the DIY experts of The Family Handyman Magazine
Cut and assemble a band saw box
1 of 1
Cut the sides and lid with a guide. Then freehand cut the center.
Here’s a quick project that family and friends will love
as a gift: band saw boxes. In less than an hour of sawing,
gluing and contour sanding, you’ll create a four-sided
box and lid that looks almost seamless, all from a single
piece of wood.
From a 4-in. wide x 3-in. thick x 18-in. long piece of
wood (see photos), you can make one large box and two
smaller ones. Give it a try!
- Set the fence 3/8 in. from the band saw blade and cut
both sides off the board. Be sure the board you’re cutting
has 90-degree corners and the blade is 90 degrees to
the table. Use a 10-teeth-per-inch (or more) blade to
ensure smoothly cut, nearly invisible glue joints.
- Flip the middle piece on its side and cut off another
3/8 in. slab for the lid.
- Remove the fence, trace the contour of the inside of
the box on the center piece and saw it out freehand.
(Leave the ends and the bottom 3/8 in. thick like the
sides and lid.)
- Glue the sides back on to the inside piece, placing a clamp
every few inches to create tight joints and glue seams that
won’t show when dry.
- Sand the glue joints, file and sand the box’s corners and
edges to a desired shape, add a handle and apply finish.
Turn the leftover, inner waste piece into two boxes. They’ll fit inside the larger box if you don’t add handles.
Finished boxes and cutting order
Finished Boxes and Assembly Details
Follow the numbers for the correct cutting order.