Cracked Band Saw Box Instructions
The glued and squared up blank should be 4 ½ inches deep, 6 inches wide and 13 5/16 inches tall.
Print out two patterns on 8 ½ by 14 paper, (or on regular paper but you will have to cut the pattern in half and then tape them together.) Line up these patterns one on top of the other and tape them together. Using spray adhesive, attach the two patterns to the block of wood and then drill four line up holes in the waste area. Using a razor blade, slice through the tape and remove the top pattern.
An alternate method to get the patterns on the blank would be use the pattern and carbon paper to trace the lines on to the blanks its just that you will have to do this twice and lining up the patterns becomes a little more critical.
Cut out the torn or cracked area first and the waste area between the legs. Then cut ½ inch off the back (make sure you cut off the back first before proceeding) and then the top four drawers (Note … you might want to leave the four top drawer fronts on the front piece and cut the fronts out on the scroll saw creating a tighter fitting drawer as the scroll saw has a much finer kerf but doing so will create an uneven glue up when attaching the front to the drawer as you must line up the outer edges of the crack requiring some odd sanding and shaping)
Cut off ½ inch from the front leaving the four remaining drawer fronts on this piece of wood. (Note … you may have chosen to leave all the drawer fronts on this piece in that case there will be 8 drawer fronts on this piece.)
Cut off the legs on the main body of the box as the legs are on the ½ inch thick front and back.
Cut out the four (or 8) drawer fronts on the scroll saw by drilling a 1/32nd through the fronts anywhere on the patterns lines and forcing a scroll saw blade through the hole using needle noose pliers.
Using the alignment holes and small nails, glue the remaining pattern back on the blank using spray adhesive.
Cut out the four remaining drawers.
Cut ¼ inch off the back of all drawers
Cut ½ inch off the front of ONLY the top four drawers as the bottom four drawers have previously been cut out on the scroll saw. (Unless you left all the drawers on the front that was cut off in that case ignore this step)
Hollow out all the drawers on the band saw and sand the interior cavities of the drawer and the inside faces of the front and back of the drawers.
Glue the front of the box back on the main body and sand only if you want a smooth finish on the inside but sanding on the inside sacrifices tight fitting drawers. Glue the back on, and then cut the final shape.
Start sanding … there’s lots of sanding so get over it.
The crack and the area between the legs cut out
The back cut off and the four top drawers cut out.
½ inch cut off the front and pattern reattached to the blank using the alignment holes.
The four remaining drawers cut out from the blank and the fronts cut out on the scroll saw from the ½ thick front piece.
The middle section with legs cut off
Hollow out the drawers
The front and back glued back on (once the back is glued on you won’t be able to sand on the inside)
Notes on the pattern:
I saved the file and opened and printed it using Windows paint program, what ever method you use to print the file the width measurement taken from the top corner to corner must not be greater than 6 inches or it won’t fit under a standard 14 inch band saw, if you have more clearance than 6 inches you can enlarge the pattern to suit your needs. Also note that the width at the bottom of the box is not the same as the top not that it’s important just something to keep in mind.