Bandsaw Box Puzzle ?

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Project by Don Johnson posted 07-12-2011 03:20 PM 2158 views 2 times favorited 6 comments Add to Favorites Watch
Bandsaw Box Puzzle ?
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I made this box (to Steve Marin’s design again) as a test run for my recent acquisition of a second-hand bandsaw – which is an even smaller than my existing machine, and which will be dedicated to the use of a 1/8th inch blade for cutting tight curves in boxes such as these.

Besides being slightly unusual in that the box is cut from end grain oak, my main reason for posting it before I even finished it properly, is to see how long it takes for LJ’ers to work out why it has the grey insert in the drawer – it was not an intended design feature !

-- Don, Somerset UK,

6 comments so far

View Time2beupinAZ's profile


453 posts in 2983 days

#1 posted 07-12-2011 05:36 PM

I think it is because your box was sad because it had a big nose so you gave it a smile…....

-- Tim - I usally measure twice after I cut......then I know for sure that I cut it short.....

View WVTODD's profile


120 posts in 2566 days

#2 posted 07-12-2011 06:45 PM

Has it been struck by lighting?

View thefishingschool's profile


41 posts in 3039 days

#3 posted 07-12-2011 10:55 PM

did you forget to cut the front off the droor before you cut out the inside?

-- wood takes time and effort... just like women

View Don Johnson's profile

Don Johnson

686 posts in 2802 days

#4 posted 07-12-2011 11:30 PM

Time2beupinAZ – perhaps I ought to burn in a couple of dots for eyes ???

thefishingschool – You got it!

Not only the front, but the back as well, so I assumed it was all scrap and wasted effort.

Then I thought about trying to fill the saw kerf with some softened pine strips, but the curve was too tight.

Seeking inspiration in my ‘odds and sods’ drawer – for perhaps some thick plastic sheet that might be suitable – I saw a short length of small plastic guttering – the sort used on greenhouses, etc.

By serendipidy perhaps, with just a little sanding of the drawer cut out, I managed to get the plastic and the cut out back into the drawer, and it was just about the right length to fill the slot – talk about luck! I must have cut a very smooth curve for the cut out, as it fitted beautifully.

I glued both bits in place at the front and back, and when dried, was then able to cut off the drawer front and back.
I removed the wooden cut out, leaving the plastic inside, and glued the front and back in place.
I’ll perhaps use some flocking to hide the stains in the plastic.

In the end, I was quite pleased with myself – although I had been pretty stupid originally !

PS – If I’d intended to make the plastic a design feature, I bet I would have struggled to get it right!

-- Don, Somerset UK,

View tinman_362's profile


95 posts in 2593 days

#5 posted 07-13-2011 06:16 AM

Haha, awesome

-- Robert: Life is all about the stories ~

View kiefer's profile


5619 posts in 2688 days

#6 posted 07-14-2011 05:22 AM

Nice save Don !

Thanks for sharing this fix.


-- Kiefer

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