The sharp-eyed among you that watched my last video will know I actually made three blanks from this one piece of walnut, with the intent of making bandsaw boxes. I will give you a quick review of how I made the three blanks. This is the second blank. I had a vague idea of the design I wanted to do. I did not make any plans or take any measurements. I just made this up as I went along.
This is the basic design I wanted to have on the side of the box. I used a marker so I could see the lines. Sometimes I have difficulty seeing my lines when I draw on the wood with just a pencil, especially if it is walnut. Once I made my first two cuts, I had to tape the pieces back together with painter's tape temporarily, so I could make my second cuts. I have the basic shape of the bandsaw box. In hindsight, it probably would have been better if I made these pieces individually, then glued them together afterward.
It would have been a lot easier, I think. Like I said, I am making this up as I go along. I made some relief cuts. I tried some different ways of removing the material. I wanted the sides of the box to be straight down, while having the legs flared out. The chisel was not working quite how I liked. I switched to the angle grinder with a Saburrtooth grinding burr. One of their new whisper bits that you can find in their online store. You can get 10% off by using the code CAM10 in their online store. Once I refined the shape with the rotary tool, I switched to sanding, first with the angle grinder, then the drill. I did some hand sanding, just to remove the sharp edges.
Now, it is time to work on the lid. I had to cut it down to the right size, first of all. I wanted to put a liner on the inside with some different wood. I am using some pear I had lying around. I is actually a very nice wood. After my first 45 degree cut, I made multiple cuts with the mitre saw, in order to sneak up on the correct size I needed to have a snug fit inside the box. Once I glued the pieces in, I trimmed them down with the handsaw. Then, I sanded the top flush. Once again, with this top piece, I snuck up on the size I wanted, just making multiple cuts with the mitre saw. I used a scrap piece just to hold it in place while I glued them together. I basically just aligned it by feel and eye. Originally, I did not intend to put a handle on the top, but I had a scrap left over. I decided to make a handle. My thought on the design was to match the legs of the box.
Again, once I made my first cuts, I taped it back together with painter's tape to make my second cuts and third cuts. I sanded it off to remove the bandsaw kerfs. I was very sparing with the glue, because I did not want any squeeze-out on the top. I held it in place for a few minutes, until the glue was tacky and let it dry. This is simply furniture oil. You have to let it soak in for a while, then wipe off the excess. It will cure over time. Not bad for not making any plans and making it up as I go along. I think it turned out really nice. Thanks for watching..