Texas Flag Bandsaw Box

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Project by Zonker posted 11-21-2019 02:37 AM 1036 views 3 times favorited 6 comments Add to Favorites Watch

Here are the Texas Flag Bandsaw Boxes I dreamed up on a motorcycle ride in North Texas. I had two cedar beam off cuts from our back yard pergola we had built a few years ago. I didn’t know what I wanted to do with them until the fore mentioned ride. I knew I wanted something unique and I think I got it. I started with blocks roughly 5×7 inches. I first cut the wave into the face, then cut the top and bottom waves. This way I had as much surface area on the saw table as possible. Then top and bottom waves were cut. Layout was done with a set of french curves. I sanded the face to 220 before cutting because it’s easier to sand on a solid surface than trying to sand the drawers and box separately. The rest was standard cut the back off, cut out the drawers and reassemble. Since I did these for my first craft show I made a batch of five (six if you include the prototype) The second and third pictures illustrate how I kept all the parts straight for each box and just how complicated it got. I closed the entry kerf for the drawers by simply gluing clamping them shut, this really opened up the big drawer kerf, so that had to be filled with a spline. In order to keep the colors where they were intended I carved a shallow groove to delineate the stripes and field and prevent the stain from leeching into the wrong area. Three of the five were torched to bring out the grain, the other two were so tight grained that the torching just turned into a smudge. I created a flexible stencil for the star, and after some fits and starts settled on using the stencil to pencil in the star and free handing the stain in the lines. I used Minwax Waterbased stains for the colors, after using their wood conditioner. Then a coat of wipe on poly followed by two coats of polycrylic. The oil based wipe on poly was to seal in the color and keep the polycrylic from smearing it. I got alot of positive comments at the fair but only one buyer. May have been a little proud of them, I don’t know. I do know that I’m thrilled with the results and love showing them off. In the second picture, you can see where the saw drifted on a knot at about the one o’clock position of the big drawer, I backed up, slowed my feed and recut my line. Afterward, I used a thin spline to fill the offending kerf and it’s virtually invisble. Hope you like them.

-- Larry A. - I've made a small fortune with my woodworking. The trouble is, I started with a large fortune.

6 comments so far

View BusterB's profile


2365 posts in 3247 days

#1 posted 11-21-2019 02:54 AM

Those are awesome Zonker. Well done.

-- Buster, Ocoee TN (Critics are men who watch a battle from a high place then come down and shoot the survivors - Hemingway)

View therealSteveN's profile


8828 posts in 1813 days

#2 posted 11-21-2019 04:08 AM

Making multiples is easy right….. I understand what you are saying about keeping track of so many similar pieces.

I like em all, but the ones showing the grain through the finish are my favorites. Makes em homey looking.

-- Think safe, be safe

View Jim Jakosh's profile

Jim Jakosh

26776 posts in 4344 days

#3 posted 11-21-2019 12:45 PM

Great BS boxes. I love ‘em!!

Cheers, Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View HokieKen's profile


19347 posts in 2378 days

#4 posted 11-21-2019 02:09 PM

Awesome boxes Zonker! Well done :-)

-- I collect hobbies. There is no sense in limiting yourself (Don W) - - - - - - - - Kenny in SW VA

View Ivan's profile


17004 posts in 4107 days

#5 posted 11-21-2019 02:30 PM

Awesoem collection…great souvenir

-- Ivan, Croatia, Wooddicted

View Zonker's profile


150 posts in 1090 days

#6 posted 11-22-2019 01:28 AM

Thanks everyone, they were both frustrating and fun to make.

-- Larry A. - I've made a small fortune with my woodworking. The trouble is, I started with a large fortune.

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