| Project by alanealane | posted 436 days ago | 2732 views | 25 times favorited | 21 comments | ![]() |
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Saturday September 6, 2008 I went to Wood Expo 2008 at L. L. Johnson Lumber Mfg. Co. and Johnson's Workbench in Charlotte, MI.
I GOT TO MEET SCOTT PHILLIPS (of The American Woodshop on PBS) for the second year in a row!! I sat in the front row and was no more than an arm’s reach from him most of the time. WOW!! Scott is truly just as he appears on his show: a cheerful, enthusiastic, down-to-earth, and just plain NICE guy who knows tons of things about woodworking. SCOTT EVEN PERSONALLY SHARPENED MY POCKET KNIFE FOR ME as he demonstrated some sharpening techniques on the DMT DuoSharp stone!!
He made three or four boxes on the bandsaw that he called “Puzzle Boxes”. He took a block of wood and cut every side so that it was concave. Then he ‘slabbed off’ the piece he wanted to be the bottom, cut a ‘key’ out of one corner of the box, and after sliding the key up out of the majority of the piece, he cut a sliding top. Then the core of the box was cut out with the cut starting and ending in the key pocket. The bottom got glued back on with super glue and accelerator, and a quick coat of spray-on poly was added. The key makes sure the sliding top won’t fall off until you remove the key itself. Pretty Cool!!
When I got home, I tried making my own from a gorgeous piece of Bloodwood I had just got in the mail.
Here are the results (with sanding to 180 grit and one coat of Zinsser Seal Coat Shellac):
11/12/08 HERE’S HOW TO MAKE IT!!
Here’s the link (so you don’t have to break your neck trying to read it!!):
http://i240.photobucket.com/albums/ff119/alanealane/howtomakeabandsawbox-2.gif
-- Lane Custom Guitars and Basses




































21 comments so far
Paul
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118 posts in 481 days
posted 436 days ago
That is a very cool box, I will try my luck making one also. Great pictures tell the story well, thanks for sharing.
-- Paul, La Center, Washington
SplinteredBoard
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50 posts in 498 days
posted 436 days ago
That’s totally wicked!!
Awesome box!
-- Splintered Board Podcast - Woodworker Un-extraordinaire
PurpLev
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2732 posts in 540 days
posted 436 days ago
pretty cool indeed… thanx for sharing – gave me a few ideas for future gifts :)
-- When in doubt - There is no doubt - Go the safer route.
MsDebbieP
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14159 posts in 1053 days
posted 436 days ago
oh yah!!! Wonderful job
-- ~ Debbie, Canada (http://www.execulink.com/~yohan)
brianinpa
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1365 posts in 615 days
posted 436 days ago
Very cool! Thanks for sharing.
-- Brian, Lebanon PA, If you aren’t having fun doing it, find something else to do.
Cov
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49 posts in 439 days
posted 436 days ago
I’ve been wanting to try one of these bandsaw boxes, I like the way you incorporated the key, neat idea.
-- Cov, Loomis, CA, http://www.covingtonwoodworks.com
DAN
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6438 posts in 875 days
posted 436 days ago
nice box. you have perked my interest in making one of these myself.
-- work from your heart and your spirit will live forever
scottb
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3403 posts in 1219 days
posted 436 days ago
great box!.. another thing I’ve “been gonna” do for years now.
-- I am always doing what I cannot do yet, in order to learn how to do it. - Pablo Picasso -- http://blanchardcreative.etsy.com -- http://snbcreative.wordpress.com/
Blake
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2755 posts in 766 days
posted 436 days ago
Cool! Thanks for sharing. I love the box.
-- Check out my new website! http://www.blakeweberwoodworking.com
woodyone
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234 posts in 483 days
posted 435 days ago
Wow, I like the locking system, very clever well done.
Woody.
-- Woody, UK
woodworm
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8178 posts in 482 days
posted 435 days ago
Very very nice and really puzzling bandsawn box.
This post makes me to reconsider buying BS first and Jointer next.. the opposite of the plan.
Thanks for sharing.
-- masrol, kuala lumpur, MY.
alanealane
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174 posts in 782 days
posted 435 days ago
Thanks for the kind words!! PLEASE GIVE ALL (or at least most of) THE CREDIT TO SCOTT PHILLIPS FOR COMING UP WITH THIS DESIGN. I quote him as calling it a “shop epiphany.”
Feel free to try it!! There’s another technique to making nesting boxes that Scott uses. It involves a top that lifts out instead of sliding. With either technique, if you start with a large enough block o’ wood, you can use what’s removed from the core to make another box, and another, and another…
Scott told us that this is how he proposed to his wife. He gave her a set of nesting boxes with the ring inside the very last one.
-- Lane Custom Guitars and Basses
bibb
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112 posts in 423 days
posted 422 days ago
Very nice. I am going to try to build one tonight! Thanks for the great photo tutorial!
Bibb
-- Bibb in CO at http://katanadesign.com
woodup
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145 posts in 835 days
posted 420 days ago
The curves are very enticing! Way to go! I might have to try something like this myself. Thanks for sharing!
-- Michael, Fort Worth, TX. "I wood if I could!"
Paul
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118 posts in 481 days
posted 375 days ago
I’ve been looking at this box for a couple of months now and am ready to try one, were you able to cut the key with a bandsaw? Not sure if mine will make the corners that sharp.
Thanks,
Paul
-- Paul, La Center, Washington
alanealane
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174 posts in 782 days
posted 374 days ago
Paul,
Yep. It’s a ‘BANDSAW BOX’ LOL.
Check out my description of the process above. I’m sending this to you too in a private message so you’ll get it for sure…
Let me know if you want some details. (I think I could sketch up some concepts in Paint Program so you can see exactly how I cut the box out. Just let me know your email…never mind, I’ll post some photobucket links on the project page and send the links to you too in another PM)
Have fun, and don’t forget to thank Scott Phillips if you ever get to meet him. He’s the one who gave birth to this design!!
-- Lane Custom Guitars and Basses
Paul
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118 posts in 481 days
posted 374 days ago
Thanks, I appreciate the encouragement. I think I’m ready to ‘go for it’!
-- Paul, La Center, Washington
alanealane
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174 posts in 782 days
posted 374 days ago
New Tutorial on how to make this!! See top of this page, just below the pictures…
PM me if you want a much clearer version.
-- Lane Custom Guitars and Basses
alanealane
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174 posts in 782 days
posted 374 days ago
Just converted it to a GIF file
It seems to work well.
Here’s the link:
http://i240.photobucket.com/albums/ff119/alanealane/howtomakeabandsawbox-2.gif
READ THE ENTIRE THING BEFORE ATTEMPTING TO MAKE THE BOX…PLEASE…
...and to quote Norm, “there is no more important safety rule than to wear these, safety glasses.”
But I’ll add: WEAR A RESPIRATOR TOO! THE DUST FROM MAKING A BOX ON THE BANDSAW CAN BE IRRITATING. And even if you don’t mind it, think of your health down the road. I regret the days I’ve come out of the shop and blew my nose only to find brown, black, and red stuff come out (sorry for the gross description). If that goes in your nose, imagine what sticks in your lungs and DOESN’T COME OUT!!!
Have fun!!
-- Lane Custom Guitars and Basses
Paul
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118 posts in 481 days
posted 374 days ago
Thanks very mucho for the great tutorial, it is very well done. appreciate the extra effort and I will let you know how it turns out.
Wish I had your computer skills also, I’m just a retired sales rep that was trained before television.
Paul
-- Paul, La Center, Washington
woodhawk
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4 posts in 376 days
posted 371 days ago
Hey thanks for the tutorial, very inspirational. I like small projects because they don’t require a large investment in lumber. I will be making one of these. Thanks!
-- Peace and kangaroo grease