Enhance The Saw Blade Entry Point On Your Band Saw Boxes

Many of the band saw box videos I have watched lately want you to hide the band saw blade cut line or entry point into the box.   It will hide fairly well if you are cutting in line with the wood grain, but with band saw boxes, we don’t always cut straight lines.  It is not  unusual to find your cut line crossing the grain directly or at an angle, and that is harder to hide.

For that reason and because I like the looks better, I enhance the saw blade entry point cut line and make it part of the pattern or design.   I also don’t like the sharp corners on my boxes or drawer fronts, therefore,  I round over the front and back of the box and the front of the drawer openings.   I also round over the front of the drawers.   To make my cut lines and entry point match, I round them also.

IMG_0859Before gluing the back on the box casing, it will be flexible enough that the entry point can be held open. While the two sides of the entry point are held apart, I use a small Dremel tool to round over both sides of the cut line. In some cases, I glue the entry point cut back together for strength or stability, but I always  round over the edges of the opening before I glue it.

After the band saw box is back together and I have completed the initial sanding and shaping of the box, I use a 1/8″ or 5/32″ round over bit on my router table to round over the rest of the box.  This, of course, can also be done by hand.



I have added a short video to help show how I do the round over.



My Band Saw Jewelry Boxes Are Now Available On Etsy

I have been designing and building band saw jewelry boxes for the last 12 or 13 years.   My wife and I have traveled to art shows all around the western United States to sell my boxes.   It has been a wonderful experience.  We have met so many wonderful people and made a lot of friends, but the time has now come to cut back a little.    We will now give up the art shows and sell my boxes just on the internet, either through my web site or through ETSY.com.   I have set up Band Saw Jewelry Boxes on ETSY and listed some of my boxes there.


One of the boxes that I listed is my Model 34 Necklace box.  It was designed specifically as a jewelry box.  It has 4 necklace drawers, a hidden drawer and a drawer for rings.  This particular box is made with Goncalo  Alvis on the front and back of the box, and with oak in the center.

One thing that has made my boxes so popular is that they are not only beautiful, but useful.  You can put a lot of jewelry in this box.

Why I Use Two Different Woods On My Band Saw Boxes?

Model # 35 Yin Yang - Afrimosia and Ash

The Yin Yang Box Of Afrimosia And Ash



I started using two different woods when I designed the Yin Yang Box.   I wanted to make one of the drawer fronts a contrasting color, like a regular yin yang pattern.   When I tried it,  I liked the contrast of the two different woods,  so I decided  to make the wood in the center of the box match the wood used for the drawer front.    That was an immediate hit with my customers, so I started making all my boxes with two contrasting woods.

I also found that it was less expensive to make a box with zebra wood, or some other exotic wood, front and back, and with ash or oak  in the center, than it was to make the box solid zebra wood.   It also bothered me to bury that beautiful wood in the middle of the box where no one can see it.

So, to answer your question, I like the look of the contrasting woods better than a solid color and it is less expensive.  That way I can charge a little less for my boxes.

2P-10 CA Glue for Attaching Drawer Pulls

In my last post, I mentioned that I attach the drawer pulls to the drawers of my band saw boxes, after the first staining, with a CA glue.    I also discussed gluing the drawer pulls on in the videos I made about how to build a band saw box.   The thing I keep forgetting to tell you is what kind of glue I use.    I have found the thick  2P-10 CA (cyanoacrylate) glue by FastCap to be not only fast, but strong and easy to use.   You just put a bead of glue on the pull,  position the pull where you want it,  spray on the activator, and hold it for 10 seconds and your done.   If there is some glue squeeze out,  just run a razor knife under one edge of the glue and you can lift it off in one piece.    I generally do have some glue squeeze out because  I want to use enough glue to make sure I have good coverage.    I have had better luck with the 2P-10 than any of the other CA glues that I have tried.

You can order it from  Amazon.com    or from FastCap.

On the FastCap site, there are several videos about different ways to use the 2P-10 glue that are very helpful.

How I Finish My Band Saw Boxes

Model - 12 | Three Drawer | Oval Box

Box With A Natural Looking Finish

I use a “buffed on” wax finish. I like the natural look  it gives.  It’s not real glossy or in any way artificial looking.

But to start, I sand the box smooth, and then put a coat of natural penetrating oil stain on it.    I let that dry good, usually at least 24 hours.   I then sand with 220 grit paper and at this point,  glue the drawer pulls on.   ( I find it easier to sand the drawer face without the pull, and I have fewer glue problems if the wood has a coat of stain on it.)   I then put on a second coat of the natural penetrating oil stain, but this time, I wipe it dry, and buff it good with a dry cloth.  I again let it sit for a day to dry good, and then apply the wax finish.

There are several buffing systems available.   I use one made by the Beall Co.  It is a series of three different waxes buffed onto the wood.   I checked their web site and they have a three part video on how to use their product.   They have to include a sales pitch for their products, but the “how to” part of the video is pretty good. I would suggest you take a look.  The first two parts of the videos will give you all the information you need.   The buffing kit is also available at Amazon.com or Craft Supplies USA.

Beall buffing video – part 1

Beall buffing video – part 2

Both the Beall Buffing System and the PSI Woodworking systems are available on Amazon. com.


More About Flocking Your Band Saw Box Drawer


In my last blog post, I discussed flocking the inside of your band saw box drawers, and attached a “how to” video that I made.    In that video is shown a box that I use to catch the overspray when spraying the flocking into the drawers.

I would suggest that you put your band saw box drawer inside such of a box, or some type of confined area, when you spray it, or you will have colored fibers all over your shop.  I use a cardboard box about 24″ square and about 16″ deep to catch most of the overspray when flocking. It’s easy to make and does a good job.

  • Place your box on it’s side so the opening faces you.
  • Tape a piece of waxed paper, equal to the width of the box, to the back inside wall of the box so that it just touches the floor of the box.  Tape only along the top of the paper.
  • Then fit another piece, the width of the box, on the floor of the box up against the back wall and under the waxed paper on the back wall.
  • Put a second piece on the floor, over lapping the first one, then put a larger piece in front of the box.  These papers just lay on the floor of the box.

When you get a buildup of flocking inside the box, tap the back wall, the flocking that has clung to the wall will drop to the floor of the box. Put all the flocking on one piece of paper and dump it back into your supply. I don’t see any reason to have it go all over the shop and be wasted, when it can be reused.

Finishing The Band Saw Box Drawer With A Spray-in Flocking

I have recently had several questions about finishing the inside of the drawers on my band saw boxes.   I think the best way to finish the drawer is by using a spray-in flocking.

Basically, you paint the inside of the drawer with an adhesive type paint and then while it is still wet,  spray small rayon fibers into the wet paint.   After the paint dries, dump the excess flocking out of the drawer, and you will have a nice felt looking finish inside your drawer.

Most craft stores carry a spray-in flocking kit.   I use DONJER Products.    They have small kits as well as the paint and fiber in larger quantities.   You can also get DONJER products through  Amazon.com.

I have prepared a short video on how to flock and finish a drawer. Hopefully it will be helpful.    It will give you a lot more detail than I have given you here.

                                                              Flocking Video

Prevent Paint Bleed Thru When Flocking Band Saw Box Drawers

When flocking band saw box drawers, the paint can bleed thru the open end grain of woods such as oak.   I prevent this bleed thru by coating the end grain inside the drawer with wood glue when I assemble the drawer.

I finish the inside of all my band saw box drawers with a spray-in flocking, and part of the procedure is to paint the inside of the drawer with an adhesive paint before spraying the flocking into it.   If you’re using oak and the end grain is not sealed, the paint may bleed thru the wood to the outside of the drawer, which creates a problem that is practically impossible to clean up.   I prevent this problem with the oak end grain by covering it with carpenters glue at the time I assemble the drawer.   I just smear it around on the end grain and work it into the wood.   This will completely resolve the problem.

I like to work with red oak and use it in many of my boxes.   Some wood workers, however, don’t like to use oak because of the open grain, and the potential for bleed thru when finishing the inside of the drawer.   Just take a minute to seal that end grain and you can enjoy working with oak with no problem.

 Seal the Oak End Grain to prevent Bleed Thru

Something New – A New Band Saw Box For Your Special Occasion

Golf Cart Band Saw Box

Golf Cart Band Saw Box

I have just added a new Golf Cart band saw box to our web site. I get a lot of requests for special orders or commissioned boxes, something to fill a special need or gift idea for a customer. One such request is the new golf cart. A customer brought me a picture of a golf cart and asked if I could make a band saw box that he could give to his golfing buddies for Christmas. This is what I came up with.

Another new band saw box is a cowboy boot. My cousin’s husband passed away recently from cancer, and she asked me to make a box for his ashes with a cowboy theme. I made a cowboy boot and had it engraved with his name and a picture of a horse (See below).

Cowboy Boot Urn

Cowboy Boot Urn

I then had a request to take that idea and make a cowboy boot band saw box.  The cowboy boot will be on the web site shortly. Ideas for new band saw boxes come from many different situations.

If you have an idea for a band saw box for a special person or occasion, contact me through the contact us page of the website, and I’ll see if I can help you.

Note: Most of my commissioned band saw boxes have a story similar to these two boxes. All of my commissioned boxes can be viewed on the web site under commissioned jewelry boxes on the front page of the web site.

Bandsaw Box Construction

As the name implies, band saw boxes are cut by hand on a band saw. Dave builds his boxes, starting with the raw wood, from a variety of hard woods–both imported and domestic.  After selecting the wood and milling it straight and flat, He laminates four (4) boards together to form a block about 3 to 4 inches thick, depending on the wood he is using.
Dave Watkins gluing process to make raw wood block for Bandsaw Box


From that block he cuts the box.

Dave Watkins cutting a solid wood block for a Bandsaw Box
Dave Watkins - Cutting Bandsaw box from laminated natural wood block
He generally uses two different woods on each box.  For example, if he is using zebra wood, he will sandwich either oak, ash, or walnut between the front and back piece of zebra wood.  He does most of his boxes this way, using different woods.

After the box is cut out and then reassembled, it is sanded and stained twice with a clear natural stain to bring out the natural color of the wood.  The final finish is a wax finish using the Beall buffing system.  The interior of each drawer is finished with a sprayed on rayon flocking.