I believe that in all of the articles I have read on box building the author always removes the lid from the carcass on the table saw. I’m just curious why the bandsaw isn’t used to do this. Is it because of the smoothness/roughness of the cut?
Thanks,
BobE
Replies
Yes, and also because you can make the cuts ALMOST all the way through and finish the removal with a razor blade, avoiding interior tearout.
Thank you,
I make very few boxes, but have tended to remove the lids on the band saw.
I don't think there is much advantage in doing so as by the time you have sorted out the less smooth cut and tearout, the loss of material is not a lot less than on the table saw.
You can go either way if your bandsaw is up to the task.
A tablesaw is easiest, and gives guaranteed results.
As mentioned, you set the blade to not quite cut through. After removing the lid with a knife or razor, there is very little sanding left to get two perfectly flush-mating pieces.
The challenge in box making is getting the hinge mortises cut perfectly so the two halves match up. Cutting off the box lid should be easy, and is, and getting two flush, perfectly flat halves helps a lot in getting good results with the hinge mortises.
I agree with the comments above. I have made many boxes over the years and have used my tablesaw using the technique described above, leaving just a hair’s worth of wood holding the lid to the body. I use a saw or sometimes a knife blade to remove the lid and then a chisel to clean what’s left.
However, I once took a box building class from Doug Stowe at Connecticut Valley school of woodworking. While there, using a finally tuned bandsaw with a fine blade, I cut a lid and it had minimal sanding required. However I wouldn’t trust my own bandsaw.
Kerf keepers allow you to saw all the way through at the tablesaw. You get the precision and get to cut all the way through. Some minor sanding still required. The tongue should match your blade's kerf.
And make sure you tape them in place. I had a lose one fall into the blade and rocket into my stomach and it hurt like a #%$^#%.
I use my bandsaw.
Les handling, less opportunity for error, small kerf.
YMMV
+1. I use the bandsaw for the same reason. The bandsaw blade I use (woodslicer) leaves a very modest surface signature on both cut surfaces that are quickly and uniformly removed by sanding the two components inverted on a full sheet of 120 grit abrasive paper.
The thinner kerf also minimizes evidence of the cut on the assembled box when using highly figured wood.
I much prefer the table saw with the blade set just high enough to penetrate the box wall. I cut the long sides (front and back) first. Then instead of kerf keepers I inject a small glob of hot melt near each end of the cuts so that the box doesn't collapse when I cut the ends.