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Saw Blade Storage

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Project by EarlS posted 08-19-2018 12:31 PM 1268 views 1 time favorited 14 comments Add to Favorites Watch

Earlier this summer the hinges and clasps on the plastic dado blade box finally broke off. Not too bad for 10+ years of use. About the same time, I was reorganizing shop storage and wound up without a home for the saw blades. There were a couple of boards of American Chestnut that I had been holding back for a special project. I also had seen several blade boxes posted on LJ with some clever ideas which I’ve shamelessly “borrowed”.

I also decided that the box I was making for the Leigh mortise and tenon parts wan’t working so I cut the inlay panels off and threw the rest of it away. Sometimes projects can’t be saved. The picture looks better than the box actually looks.

What better time to make a couple of storage boxes for saw blades?

The dado blade box is 7/8” thick chestnut, 12-3/4” square by 4-1/2” tall. I used the Leigh dovetail jig to make the 5/16” box joints. Rather than having a lift lid, I decided a slide lid would be more functional. 1/2” slots were cut into the sides, and the ends were shortened to accommodate sliding the lid on/off. One of the inlays was laminated to a piece of chestnut and planed to 7/8”. A dado was used to make the rabbet for the sides of the lid to fit the slots in the side of the box.

The bottom is cottonwood, with inset rings for the blades and spacers. The small circle jig and router made quick work of both circles. The centers from the blade holders were planed to 1/8” and 5/8” holes were added. A couple of 5/8” dowels provided the spindles for the blades and spacers.

In order to accommodate 6 – 10” blades the blade box is also 7/8” chestnut, 12-3/4 square by 7-1/4” tall. The blade box was similar construction, except the box joints are 5/8”. Leigh has a decent method of using a spacer to get the larger box joint. After setting it up and working with it, I wonder if different sized box joints could be achieved with a homemade spacer and modified procedure. That’s something I will save for another project

The blade cases are made from cottonwood, planed to 1/2” with a 1/4” inset circle routered into the piece. An 8” diameter circle was cut out to provide the spacers for the dado blades as well as providing an easy access for removing the blades from the sleeves. Side note – there are plastic blade sleeves out there as well as a plan to make a blade box using them.

The front box joints were “completed” using scrap wood as the “front panel” and flush cutting the “front” piece at the joint, leaving a box joint. The slots for the blade sleeves were lined up with the box joints, making sure that the cuts lined up with the short side fingers so the slots wouldn’t show up in the back corner joints.

Since the top doesn’t need to open, the 1/2” thick inlay panel is glued in place and pinned to the sides with Miller Dowels. They were supposed to be cherry but look suspiciously like oak.

Everything was sanded to 220 grit, sealed with a coat of Seal-A-Cell, lightly sanded with 600 grit, then topped with 2 coats of hand wiped Arm_R-Seal and final sanded with 2000 grit, and finally waxed with Behlen’s Deluxing Compound (this is my standard finish).

Now I need to build a shelf to put these beauties on.

-- Earl "I'm a pessamist - generally that increases the chance that things will turn out better than expected"





14 comments so far

View Dave Polaschek's profile

Dave Polaschek

2701 posts in 756 days


#1 posted 08-19-2018 12:49 PM

Nicely done, Earl. Way to class up the shop!

-- Dave - Minneapolis

View TungOil's profile

TungOil

1040 posts in 669 days


#2 posted 08-19-2018 01:59 PM

That is some seriously fancy blade storage!

-- The optimist says "the glass is half full". The pessimist says "the glass is half empty". The engineer says "the glass is twice as big as it needs to be"

View Handtooler's profile

Handtooler

1628 posts in 2306 days


#3 posted 08-19-2018 02:26 PM

Absolutely beautiful work on those very useful boxes. Keep ‘em waxed and lookin’ spiffy!

-- Russell Pitner Hixson, TN 37343 bassboy40@outlook.com

View WhattheChuck's profile

WhattheChuck

339 posts in 3734 days


#4 posted 08-19-2018 03:44 PM

Next level, Earl! After the guys with the white coats drag you away, I wanna come to your garage sale! ;-)

-- Chuck, Pullman, WA

View HokieKen's profile

HokieKen

6605 posts in 1312 days


#5 posted 08-19-2018 03:51 PM

Geeze Earl! That’s just stupid awesome!

-- Kenny, SW VA, Go Hokies!!!

View BurlyBob's profile

BurlyBob

5936 posts in 2439 days


#6 posted 08-19-2018 03:52 PM

Those are both fantastic boxes. That inlay top is superb.

View James E McIntyre's profile

James E McIntyre

177 posts in 1466 days


#7 posted 08-19-2018 04:43 PM

That is one beautiful storage box.
Should Be in a museum.

-- James E McIntyre

View pottz's profile

pottz

3350 posts in 1158 days


#8 posted 08-19-2018 05:33 PM

i dont think ive ever seen a nicer way to store saw blades,beautiful box.

-- sawdust the bigger the pile the bigger my smile-larry,so cal.

View mel52's profile

mel52

559 posts in 438 days


#9 posted 08-19-2018 08:08 PM

Great looking and cool designing. Good job !!!!!

-- MEL, Kansas

View Peteybadboy's profile

Peteybadboy

501 posts in 2123 days


#10 posted 08-19-2018 09:18 PM

I really like the lid design, I’ve been thinking of something similar. Thanks for postingh

-- Petey

View mikeacg's profile

mikeacg

714 posts in 1231 days


#11 posted 08-20-2018 12:45 AM

You don’t do anything halfway, that’s for sure! I thought it was a repeat of your project from the Box Swap but then realized the design was more angular! Beautiful job once again!
Way too nice for my shop… And I just realized that I didn’t design a space in the new shop for my glass working tools! Gonna have to steal some space from the CNC room I guess…

-- Mike, A Yooper with a drawl, http://www.artcentergraphics.com

View jeffswildwood's profile

jeffswildwood

3552 posts in 2151 days


#12 posted 08-20-2018 11:53 AM

What a beautiful way to store blades! There’s no reason something for the shop can’t look nice.

-- We all make mistakes, the trick is to fix it in a way that says "I meant to do that".

View splintergroup's profile

splintergroup

2341 posts in 1396 days


#13 posted 08-20-2018 06:14 PM

The tray concept looks really handy for protection and compactness, but only six blades Earl? come on! 8^)

I’m awed by your classy approach to your projects, even shop items!

View Joe's profile

Joe

482 posts in 1260 days


#14 posted 08-20-2018 08:44 PM

Excellent workmanship, Beautiful way to store your saw blades. Thanks for inspiring

-- CurleyJoe, "You only learn from your mistakes"

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