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.