Popular Woodworking 2009-04 № 175, страница 48

Popular Woodworking 2009-04 № 175, страница 48

This undulating band saw box is simple to make, and it makes a great gift.

BY DAVID THIEL, JIM STACK & LOIS KEENER VENTURA

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JL.es, you could say building this box is like dancing. Your partner is that beautiful wood you've just found or have been secretly saving for the past decade, and the music is the sound your tools make.

This band-sawn box design is an intermediate project due to the number of drawers and amount and type of carving involved. The carvingand shaping can be done quickly with coarse-through-fine sandpaper on a belt sander, oscillating spindle sander and with sandingdrumson a portable drill, then refined with a finishing sander and hand sanding. Some of the carving - mainly at the saw kerfs - must be done with straight chisels and lots of coarse-through-fine sandpaper wrapped around dowels, flexible rubber sanding accessories if you have them, and, of course fingers. (You definitely need these, so take special care around a running band saw blade!)

When selecting wood, look for grain patterns that are exceptional. Burls, curls, spalt-ing, unusual colors and yes, even cracks, splits, worm or bug holes and checkscan be used to create a box that will truly be one of a kind.

When you cut a board into shorter lengths, inspect the end grain and match them to each other when gluing up a blank for your box, such as bookmatching. This can make your box sing a tune that no one has ever heard.

— LKV

Make the Carcase from a Block

The photos on the following pages will take you step by step through the building process, but an overview here will be helpful.

First select your wood, choosing a nice-looking grain pattern. You'll probably need to glue up a sandwich to achieve your desired thickness (which can vary according to your likes). Wooden handscrewsarethe best clamp choice for this step, applying even pressure at all points on the glue-up.

Flatten the bottom squarely to the back of your box blank. A jointer is the easiest tool to use for this, but a handplane, disc sander or stationary belt sander will also work.

Twister. The organic curves and custom pulls in this eye-catching design can be made from any combination of woods.

58 ■ Popular Woodworking April 2009

HAD PHOTO BY Al MMBSH; SUP PHOTOS BY OAVTO TMl

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