Now that you’ve decided upon the shape of your bandsaw box and transferred it to the wood via your preferred method, it’s time to get to cutting it out. Just from working on this project a little bit, I’d recommend a 1/4” blade, or smaller. I started with a 1/4”, 4-TPI, then switched down to a 3/16”, 10-TPI. Between these 2-blades, the 1/4”-blade cuts more easily and quicker through the wood, but is not able to make as tight of a turn as the 3/16”-blade.
Just as a refresher, this is the shape we’re going to cut out:
Here’s what it looks like after the cutting is done:
Here are all the scraps that were cut away (I did not try to do one continuous cut, even though I could’ve with the way the line was drawn…and don’t worry, I wasn’t running the bandsaw that way, simply had taken the tension off the blade):
I’m going to also go ahead and sand the outside shape to remove the blade lines that reared their ugly head while sawing the perimeter of the oval. I’d suggest doing this now before cutting anything else off or out because the block of wood still has all of it’s strength so it’ll hold up better to any harder shaping you might want to do right now. In addition, if you sand to the outer shape that you want now, the front and back pieces will mate up perfectly once cut off and glued back on. You’ll still have some sanding to do later, but if you can get it close now, you’ll probably be better off in the long run, as per the above reasons.
Sorry, I don’t have any “before” pictures showing the blade marks, but here’s what it looks like after sanding it down a bit with my ROS and by hand, all just with 60-100-grit paper:
In addition to sanding with a little block of wood and the ROS, I also used a socket to wrap the sandpaper around in order to sand the curved legs:
-- Jonathan, Denver, CO "Constructive criticism is welcome and valued as it gives me new perspectives and helps me to advance as a woodworker."