Well I went to the attic, actually surface area of the wood rack in the workshop and picked up a Bigleaf Maple Burl piece that I bought about 5 years ago on eBay. It came from the Pacific Northwest of the USA.
The piece had been water blasted to remove all of the bark off the outer edge of the burl and that leaves the spikes that are seen here. The block had been dipped in wax to minimize the drying of it.

I then went to the jointer (spiral Carbide blades) and cleaned up the edges.


I identified the same side on the pieces to be cut next.
The block has a slope on the bottom. That was the way it came to me and so I’m keeping the same slope. I’ll make the bottom flat, but it will have an angle to the two sides. The front and back will be at a 90 deg.
I now cut off the top and bottom to get the center block.
The angle is visible in this shot.
I now marked the cut line for the core of the box.
And that is where I stopped tonight. I need to dig out the small Sears Craftsman 12” bandsaw that I’ve owned for 35 years. I keep finer cut blades in it than I do in the big saw. I used a carbide tipped resaw blade to make the saw cuts shown for the top and bottom cutoff. No sanding is required on these cuts.
The reason that one side is wider than the other is so that I don’t cut through on the angle. BUT, that is also a design issue. Don’t make everything the same size because this is a small box and differences like this make it unique.
-- What happens in the workshop stays in the workshop. No wait that doesn't sound right. Karson Southern Delaware karson_morrison@bigfoot.com †






















22 comments so far
mot
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4903 posts in 932 days
posted 693 days ago
I’m glad you’re doing this, Karson. Thanks for the explanation. It should serve as a good read!
-- You can discover more about a person in an hour of play than in a year of conversation. (Plato)
DrSawdust
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231 posts in 994 days
posted 693 days ago
This is going to make a great gift.
-- Making sawdust is what I do best
Jamie
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146 posts in 710 days
posted 693 days ago
Thanks for the step by step Karson.. That box is going to be beautiful, you can already see the depth of the figuring where you marked the core cut line. Great piece of wood.
-- Jamie, Kentucky
David
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1982 posts in 1035 days
posted 693 days ago
Karson -
This is going to be a beautiful box. I always enjoy these step-by-step blogs!
-- http://foldingrule.blogspot.com
cajunpen
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5968 posts in 962 days
posted 693 days ago
Karson the first thing that amazes me is that you could put your hands on a piece of wood that you purchased 5 years ago. I say this because I’ve read and have seen pictures of your vast and very impressive wood stock and shop. I can set a piece of wood down and 10 minutes later I can’t find it :-)).
I am anxious to follow your blog on this box – it looks like you are off to a great start.
-- Bill - "Suit yourself and let the rest be pleased." http://www.cajunpen.com/
Karson
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25803 posts in 1296 days
posted 693 days ago
Bill.
These pieces are / were so small that I put them up on top of the wood rack. When I built the rack I put a 3/4” plywood top on it. Partly to keep the wood rack from twisting because of any uneven wood stacking or other pressures.
I probably need to post a project on the wood rack. Too bad I didn’t take pictures when building.
So a bunch of wood chunks of big leaf maple that I’ll probably use for wall clocks and a small set of bandsawn boxes that I was going to make for the ladies in my life. My wife, daughters and daughter-in-law. These pieces were stored on top with the veneers etc.
I might have to search out some more of these wood chunks, when I finally get around to making them all.
I also have a slice of a burl that is over a 3’ circle and about 1 – 1 1/2” thick would make a great table top but I know my wife would not like it with all of the spikes sticking out straight just waiting to grab anyone that walks by. You would end up with punctures all over your body. The table might last 15 minutes. Then I’d have to figure what else to do with it.
-- What happens in the workshop stays in the workshop. No wait that doesn't sound right. Karson Southern Delaware karson_morrison@bigfoot.com †
dalec
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580 posts in 784 days
posted 693 days ago
Karson, Thanks for taking us along with you as your start your project. I am excited to see the project from start to finish.
Dalec
rikkor
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11335 posts in 771 days
posted 693 days ago
Karson, we all appreciate the level detail that you put into your posts. Thanks so much.
MsDebbieP
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14160 posts in 1057 days
posted 693 days ago
this blog series will be fun to watch – and educational and inspirational
-- ~ Debbie, Canada (http://www.execulink.com/~yohan)
Scott Bryan
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20716 posts in 718 days
posted 693 days ago
Karson I want to thank you for the blog. Never would I have imagined seeing a box inside of the burl piece. To me it just appeared to be a chunk of wood best destined for the fireplace. This work is truly educational. I just received my Powermatic band saw yesterday and this definitely gives me ideas with which to put it to use (once it is assembled of course). Thanks for the inspiration. Keep us posted on your progress.
-- With God's help all things are possible- even woodworking. Woodworking is not just a hobby, it is an (expletive deleted) expensive hobby.
MsDebbieP
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14160 posts in 1057 days
posted 693 days ago
a burl in the fireplace… that would be like painting walnut, wouldn’t it?
-- ~ Debbie, Canada (http://www.execulink.com/~yohan)
Jeff
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996 posts in 990 days
posted 693 days ago
Looking forward to it, Karson. I read about these. I hear about these. But now I get the benefit of your in-depth explanations. Thanks!
-- Jeff, St. Paul, MN
Jiri Parkman
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603 posts in 709 days
posted 693 days ago
Thanks for that. I’m looking looking forward for other patr of this series.
-- Jiri
SPalm
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949 posts in 778 days
posted 692 days ago
Thanks Karson.
What a pretty piece-o-wood.
(Another subtle plug for spiral jointers and carbide BS blades.)
-- Stevethepeeve -- I'm no rocket surgeon
Karson
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25803 posts in 1296 days
posted 692 days ago
If it makes the job easier and more foolproof I’m for it. I’ve lived with the chipout and rough sawn edges. And I now marvel at the new features in tools that can make our hobby/jobs easier.
-- What happens in the workshop stays in the workshop. No wait that doesn't sound right. Karson Southern Delaware karson_morrison@bigfoot.com †
jockmike2
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7325 posts in 1143 days
posted 692 days ago
Why did’nt you do this” before”I made mine so I knew how to do it right. You are a stinker no you’re not you’re a big stinker. LOL mike
-- Mike. mwurm13@yahoo.com
Russel
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2061 posts in 835 days
posted 692 days ago
I had never heard of bandsaw boxes till I found this place, and then having seen some here I was a bit intimidated. I’m looking forward to watching this develop.
-- Working at Woodworking www.VillageLaneFurniture.com
Lee A. Jesberger
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3710 posts in 876 days
posted 692 days ago
Hey Karson;
I’m beginning to believe you have more toys than me. There’s still time though.
Nice block of Maple. I have a piece in the shop I bought about five years ago also. Maybe you’ll inspire me to do something with it.
Right now it’s sitting on a shelf, acting as a decoration.
I’ll be watching for further updates.
Happy Holidays;
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Grumpy
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14926 posts in 747 days
posted 691 days ago
Keep up the good work Karson. Thats a nice piece of burl.
-- Grumpy - "Always look on the bright side of life"- Monty Python
Dick, & Barb Cain
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7039 posts in 1195 days
posted 667 days ago
Fantastic! Karson,
I’m sorry that I missed this blog earlier,
you’re always coming up with something very different.
Good Luck!!!
-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN. http://www.woodcarvingillustrated.com/gallery/member.php?uid=3627&protype=1
Karson
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25803 posts in 1296 days
posted 666 days ago
Thanks Guys.
-- What happens in the workshop stays in the workshop. No wait that doesn't sound right. Karson Southern Delaware karson_morrison@bigfoot.com †
SteveKorz
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2030 posts in 610 days
posted 295 days ago
Great series Karson (and a nice little box)!
-- As iron sharpens iron, so one man sharpens another. (Proverbs 27:17) †