This project was built and designed by Caleb from Caleb’s Fine Woodworking. It’s a detailed yet approachable tutorial for making a bandsaw box—a compact, artistic storage solution that combines curved joinery with clean design.
With just a few pieces of hardwood and careful attention to shaping, Caleb demonstrates how to turn a block of wood into a functional drawer box using only a bandsaw, sander, and some glue. This is a great project for building skill with curves, templates, and tight-fitting parts.
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Choosing and Preparing the Wood
The first step in this build is material selection. Caleb chooses maple for the core of the box and sandwiches it between two thinner cherry panels for contrast and strength.
This combination of woods not only looks great but also makes the box more stable during cuts. The boards are cut into strips slightly larger than the intended template dimensions, giving room to refine the shape later.
Attaching the Template
A custom template is used to guide the curved bandsaw cuts. Caleb modifies an existing design to suit his vision and adheres it to the front of the blank using spray adhesive.
This template becomes the blueprint for the entire project. Making sure it’s centered and securely fixed is essential, as it directs all following cuts.
Cutting the Box Outline
Once the blank is assembled and the template applied, Caleb heads to the bandsaw to cut out the exterior shape of the box. He stays just outside the lines, giving himself some margin for sanding and smoothing later.
After the rough cut is complete, the shape is cleaned up using a belt sander. This step removes saw marks and fine-tunes the curves so the box looks smooth and intentional.
Creating the Drawer Section
To begin building the internal drawer, Caleb first cuts off the back panel of the box. This is done with a careful, straight cut to keep the back clean and usable.
The drawer itself is then sliced from the center of the remaining block. The face and rear of the drawer are kept intact and set aside while the internal material is hollowed out, forming the drawer cavity.
Assembling the Drawer Box
The hollow drawer body is glued back together using a light bead of glue around the outer edge. Once dry, the face and back pieces are reattached, forming a full, hollow drawer that fits tightly inside the original box shell.
Caleb uses a spindle sander to refine the curves inside the drawer, smoothing out any irregular cuts and giving the interior a more professional look. Every small adjustment at this stage improves the drawer’s function and appearance.
Sanding and Shaping the Exterior
With the drawer complete, attention returns to the outer shell. The back panel is glued back into place, and any rough transitions are sanded flush.
To elevate the look and improve ergonomics, Caleb rounds over the drawer edges using a router. During this step, a slip with the router causes a deeper cut than intended—but instead of scrapping the piece, he transforms it into a functional notch for easier drawer access.
Applying the Finish
Once the shaping is done, everything is sanded smooth and prepped for finish. Caleb uses Rubio Monocoat, a durable hard-wax oil that enhances the natural grain while offering protection.
The finish is applied with a cloth, worked into the wood, and wiped clean. The contrast between the maple and cherry becomes more vivid, and the smooth curves take on a polished, professional appearance.
A Small Project with Big Payoff
This bandsaw box is compact, but it offers a wide range of techniques in a single build. From using templates and cutting curves, to creating friction-fit drawers and applying a refined finish, it’s a rewarding process from start to finish.
Caleb’s method shows how woodworking isn’t just about precision—it’s also about adaptability. Turning a mistake into a functional design choice is a good reminder that not every build goes exactly as planned, and that’s okay.
Ideal for Woodworkers at Any Level
Whether you’re just getting started or have years of experience, this project offers a challenge with plenty of flexibility. It also makes a great gift or sellable item, thanks to its visual appeal and practical use.
The real value is in learning how to combine artistic shaping with mechanical precision—all from a single block of wood and one versatile tool.
Please support Caleb by visiting his website: https://www.calebscustomwoodworks.com/.