Saw Blade Storage

  • Advertise with us
Project by EarlS posted 08-19-2018 12:31 PM 1949 views 2 times favorited 14 comments Add to Favorites Watch

Earlier this summer the hinges and clasps on the plastic dado blade box finally broke off. Not too bad for 10+ years of use. About the same time, I was reorganizing shop storage and wound up without a home for the saw blades. There were a couple of boards of American Chestnut that I had been holding back for a special project. I also had seen several blade boxes posted on LJ with some clever ideas which I’ve shamelessly “borrowed”.

I also decided that the box I was making for the Leigh mortise and tenon parts wan’t working so I cut the inlay panels off and threw the rest of it away. Sometimes projects can’t be saved. The picture looks better than the box actually looks.

What better time to make a couple of storage boxes for saw blades?

The dado blade box is 7/8” thick chestnut, 12-3/4” square by 4-1/2” tall. I used the Leigh dovetail jig to make the 5/16” box joints. Rather than having a lift lid, I decided a slide lid would be more functional. 1/2” slots were cut into the sides, and the ends were shortened to accommodate sliding the lid on/off. One of the inlays was laminated to a piece of chestnut and planed to 7/8”. A dado was used to make the rabbet for the sides of the lid to fit the slots in the side of the box.

The bottom is cottonwood, with inset rings for the blades and spacers. The small circle jig and router made quick work of both circles. The centers from the blade holders were planed to 1/8” and 5/8” holes were added. A couple of 5/8” dowels provided the spindles for the blades and spacers.

In order to accommodate 6 – 10” blades the blade box is also 7/8” chestnut, 12-3/4 square by 7-1/4” tall. The blade box was similar construction, except the box joints are 5/8”. Leigh has a decent method of using a spacer to get the larger box joint. After setting it up and working with it, I wonder if different sized box joints could be achieved with a homemade spacer and modified procedure. That’s something I will save for another project

The blade cases are made from cottonwood, planed to 1/2” with a 1/4” inset circle routered into the piece. An 8” diameter circle was cut out to provide the spacers for the dado blades as well as providing an easy access for removing the blades from the sleeves. Side note – there are plastic blade sleeves out there as well as a plan to make a blade box using them.

The front box joints were “completed” using scrap wood as the “front panel” and flush cutting the “front” piece at the joint, leaving a box joint. The slots for the blade sleeves were lined up with the box joints, making sure that the cuts lined up with the short side fingers so the slots wouldn’t show up in the back corner joints.

Since the top doesn’t need to open, the 1/2” thick inlay panel is glued in place and pinned to the sides with Miller Dowels. They were supposed to be cherry but look suspiciously like oak.

Everything was sanded to 220 grit, sealed with a coat of Seal-A-Cell, lightly sanded with 600 grit, then topped with 2 coats of hand wiped Arm_R-Seal and final sanded with 2000 grit, and finally waxed with Behlen’s Deluxing Compound (this is my standard finish).

Now I need to build a shelf to put these beauties on.

-- Earl "I'm a pessamist - generally that increases the chance that things will turn out better than expected"

14 comments so far

View Dave Polaschek's profile

Dave Polaschek

5382 posts in 1353 days

#1 posted 08-19-2018 12:49 PM

Nicely done, Earl. Way to class up the shop!

-- Dave - Santa Fe

View TungOil's profile


1382 posts in 1266 days

#2 posted 08-19-2018 01:59 PM

That is some seriously fancy blade storage!

-- The optimist says "the glass is half full". The pessimist says "the glass is half empty". The engineer says "the glass is twice as big as it needs to be"

View Handtooler's profile


1628 posts in 2903 days

#3 posted 08-19-2018 02:26 PM

Absolutely beautiful work on those very useful boxes. Keep ‘em waxed and lookin’ spiffy!

-- Russell Pitner Hixson, TN 37343 [email protected]

View WhattheChuck's profile


402 posts in 4332 days

#4 posted 08-19-2018 03:44 PM

Next level, Earl! After the guys with the white coats drag you away, I wanna come to your garage sale! ;-)

-- Chuck, Pullman, WA

View HokieKen's profile (online now)


14009 posts in 1910 days

#5 posted 08-19-2018 03:51 PM

Geeze Earl! That’s just stupid awesome!

-- Kenny, SW VA, Go Hokies!!!

View BurlyBob's profile


7600 posts in 3037 days

#6 posted 08-19-2018 03:52 PM

Those are both fantastic boxes. That inlay top is superb.

View James E McIntyre's profile

James E McIntyre

799 posts in 2063 days

#7 posted 08-19-2018 04:43 PM

That is one beautiful storage box.
Should Be in a museum.

-- James E McIntyre

View pottz's profile


9856 posts in 1756 days

#8 posted 08-19-2018 05:33 PM

i dont think ive ever seen a nicer way to store saw blades,beautiful box.

-- working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.

View mel52's profile


1445 posts in 1036 days

#9 posted 08-19-2018 08:08 PM

Great looking and cool designing. Good job !!!!!

-- MEL, Kansas

View Peteybadboy's profile


1957 posts in 2721 days

#10 posted 08-19-2018 09:18 PM

I really like the lid design, I’ve been thinking of something similar. Thanks for postingh

-- Petey

View mikeacg's profile


1532 posts in 1829 days

#11 posted 08-20-2018 12:45 AM

You don’t do anything halfway, that’s for sure! I thought it was a repeat of your project from the Box Swap but then realized the design was more angular! Beautiful job once again!
Way too nice for my shop… And I just realized that I didn’t design a space in the new shop for my glass working tools! Gonna have to steal some space from the CNC room I guess…

-- Mike, A Yooper with a drawl,

View jeffswildwood's profile


4449 posts in 2749 days

#12 posted 08-20-2018 11:53 AM

What a beautiful way to store blades! There’s no reason something for the shop can’t look nice.

-- We all make mistakes, the trick is to fix it in a way that says "I meant to do that".

View splintergroup's profile


3778 posts in 1994 days

#13 posted 08-20-2018 06:14 PM

The tray concept looks really handy for protection and compactness, but only six blades Earl? come on! 8^)

I’m awed by your classy approach to your projects, even shop items!

View Joe's profile


527 posts in 1858 days

#14 posted 08-20-2018 08:44 PM

Excellent workmanship, Beautiful way to store your saw blades. Thanks for inspiring

-- CurleyJoe, "You only learn from your mistakes"

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics