Butterfly bandsaw box

[swampgator]

Well, I keep trying to post pics here and even when they are reduced to 500 X 660, can't get them to load. I just wanted to show other beginners how I do this. This one is getting to be a rather intensive project. So, if you see this and have questions or have comments, please post them.

http://www.handymanclub.com/connect/for ... 946#286783

[BuckeyeDennis]

I can't wait to see the finished butterfly box. It should be way cool. On the other hand, I really hope that my teenage daughters do NOT see it, cuz I have way to many projects queued up anyway!

[JPG]

Well, I keep trying to post pics here and even when they are reduced to 500 X 660, can't get them to load. I just wanted to show other beginners how I do this. This one is getting to be a rather intensive project. So, if you see this and have questions or have comments, please post them.

http://www.handymanclub.com/connect/forums/aft/49946#286783

Max size = 800 x 600.

660 is greater than 600!;)


Interesting box.

[bosox]

Very interesting!Looking good. I can't wait to see the finished band saw box!

[heathicus]

If you host the images at a service like Photobucket, Flickr, Picassa, etc, then link to them using the IMG code in the post here, you're not restricted to 800x600.

[swampgator]

Max size = 800 x 600.

660 is greater than 600!

Thanks, JPG. I had the assumption that it was the whole area or total mb. Thanks for making that clear. I'll resize and hope to keep the clarity and proportions. Will post if I can so no one will have to click the link.

Buckeye, I hope your daughters don't see it either. When the man cut down the tree and threw out those chunks, he said he didn't know what I was going to do with those. So, just put them on the concrete floor of the garage and let them dry. Wanted to do a bandsaw box, and this looked like the wood I needed. I suppose it would have been better turned.

Thanks everyone for the compliments and kind words. I really do appreciate it.

[ATTACH]20205[/ATTACH] Started with several chunks of wood that the tree cutter thought these would have no use. The rest of the cedar tree is cut into 1" and 2" boards. I just wanted to get these chunks out of the garage. A photo that I don't have is one with the pattern on top so it can be seen to cut the wood.

[ATTACH]20206[/ATTACH]
This photo is after the outside pattern is cut and after I tried to cut a consistent thickness for walls of the box. You can see the entry and exit points here.

[ATTACH]20207[/ATTACH]
This is after the hollowed parts are extracted and sitting on the SS table saw. More to follow.

[swampgator]

[ATTACH]20209[/ATTACH]
OK, this one is out of sequence. This one is trying to get the outside parts set up for gluing, but we have much to do before then. Since the butterfly is too large to fit through the bandsaw to remove the bottom and top of the box, had to do it with a flush cut saw. Therefore, the panels are not even. Will have to glue the broken pieces back together, then sand so they will fit their respective places.

[ATTACH]20208[/ATTACH]
Another view with emphasis of the inside.


[ATTACH]20210[/ATTACH]
Next picture is tray and it's bottom cut. Will show the hollow of it next.

[swampgator]

[ATTACH]20213[/ATTACH]
Cutting out the tray. Yes, cut at a 25 degree angle so when she has it out, the rings can be seen at a lower angle. Will cut off most of the center point.

[ATTACH]20214[/ATTACH]
Will first glue the entry point together. After first glue point dries, will glue the bottom to the tray. Will sand. That picture is coming just as soon as I can retake it. Can't get it to email from my phone.

[swampgator]

[attach]20222[/attach]

Forgot to attach this picture earlier in the thread. So this is what it looked like right after cutting it out and before cutting out the middle.

[attach]20223[/attach]

This is the little tray that is glued out and now sanded. Because of the size changing due to clamping the cut, the bottom was larger. Used a dremel sanding drum to take it down and then used 100 grit to make it look like one piece. Finished with 320 grit sandpaper and this is the result. Inside will be covered in red felt, with rows to store rings.

[attach]20224[/attach]

This is how it looks in the box. Another tray will be put on the other side with the same type of supports. It won't be cut at an angle. Will show it after it is glued.

[swampgator]

[attach]20225[/attach]

This is the second tray. Debating with myself whether to leave the bottom where it is to conceal what is in the bottom or conform it to the rest of the tray. Also, shown here are the small support that will hold the tray off the bottom without taking up much space in the bottom of the box.

[attach]20226[/attach]

Here is almost what it will look like once glued and inserted. The little pill bottle contains sanding dust. This dust will be used to make a mixture with glue to conceal defects.

[attach]20227[/attach]

This is one of the finest parts of the Shopsmith to me. I never put the box more than half way down the sanding disk because of all the resistance and stress. Much more, even at the slowest speed, it can throw it out at the user or shatter into pieces which in turn will fly back at the user. The nice thing is to advance the quill gently so as not to cause the box to build up too much stress and resistance. The object here is to get the top and bottom edges straight so that the bottom will glue up nicely. Also, the lid will simply sit on the box and look professional.

Will be back when the felt is in place. Thanks for watching.