Cut and assemble a band saw box
Band saw cutting order
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 Assembly Details
Follow the numbers for the correct cutting order.
Required Tools for this Project
Have the necessary tools for this DIY project lined up before you start—you’ll save time and frustration.
- Wood glue
Required Materials for this Project
Avoid last-minute shopping trips by having all your materials ready ahead of time. Here’s a list.