1st step in making the box is selecting the timber and marking the timber for the box sides.

Select a piece of timber 35mm x 22mm x 270mm long. This piece is enough timber for the box side.

Earlier I spoke about the importance of grain matching the box sides, this is the same when your making pen kits and cutting pen barrels. So to help with the grain matching process later on, we need to mark the timber so we can put it back together in order.

1st mark the centre of the timber where we will split on the band saw. Then mark where we are going to cut the mitres.

Mark 2 X’s along the centre line. This centre line is actually the outside face of the box. We then mark them with a A, B, C and D with a line joining them. I do batches of boxes at a time, so I also give each piece a unique number on both side of the centre line. This is because if your making 10 boxes of the same species of timber, it quite easy to confuse yourself with which pairs goes together.

Once the timber box side blanks are fully marked, we can then split the blank on the band saw. You can use any method your comfortable with, like a hand saw or table saw. I like using the band saw because the kerf of the band saw blade is quite small compared to a table saw (3.2mm).

The timber on the video is kiln dried PNG Rosewood. Even though the timber is already kiln dried, after splitting in half, I will let the timber dry for another 3 – 6 months. This just lets the timber de-stress it self out in the racks rather than when it is completed as a box. If the timber moves again after sawing, we can later machine out any warping, cupping or twisting.