Batman Bandsaw Box - Relaxing DIY Woodworking in the Garage

"It's not who I am underneath, but what I do that defines me." And what I do... is make sawdust.

The Bandsaw Box is a classic woodworking project. It looks magical—a seamless wooden block with a drawer cut out of the center. There is no traditional joinery. No screws. No nails. Just a bandsaw blade and clever gluing.

For this build, I decided to pay homage to the Caped Crusader by shaping the box like the iconic Batman logo. The combination of Walnut (dark, like the Knight) and Maple (light contrast) makes it pop.

What is a Bandsaw Box?

If you are new to this:

You take a solid block of wood.
You slice off the back.
You cut out the "core" (which becomes the drawer).
You glue the back on.
You hollow out the core. It is a subtractive sculpture process rather than additive construction.

Material & Tools

Lumber

Walnut: 8/4 (2-inch thick) stock if you can find it. If not, laminate 1-inch boards together. I used Walnut for the "Wings".
Maple: A strip down the center for contrast or for the handle.

Tools

Bandsaw: This is the star of the show. You need a blade that can turn tight corners. I recommend a 3/16" or 1/8" blade. A standard 1/2" resaw blade will not make the tight turns of the Bat-symbol.
Spindle Sander: Unless you want to sand convex curves by hand for 6 hours (you don't), a spindle sander is essential.
Clamps: Deep throat clamps are helpful.

The Build Process

Step 1: The Lamination (Making the Block)

I didn't have a single piece of wood 5 inches thick. So, I made a "wood sandwich."

Glue Up: I glued layers of Walnut and Maple together to create a block roughly 6" x 10" x 5".
Grain Direction: Make sure the grain runs in the same direction for all layers to avoid expansion issues.

Step 2: The Template

I printed the Batman logo on paper and used spray adhesive (3M Super 77) to stick it directly to the wood block.

Tip: Put masking tape on the wood first, then glue the paper to the tape. It peels off much cleaner later!

Step 3: Cutting the Body (The Outer Shape)

I carefully traced the outside line of the logo on the bandsaw.

Technique: Keep the wood moving. If you stop in a cut, the blade friction burns the wood, leaving black marks that show up in the finish.
Save the Offcuts!: Sometimes the offcuts can be used for box feet or handles.

Step 4: Slicing the Back

I set up a fence and sliced a 1/2" slab off the back of the shape. This is the "lid" for the back. Label it! You want to glue it back on in the exact same orientation so the grain matches perfectly.

Step 5: The Core (The Drawer)

This is the magic trick. I entered the cut from a sharp corner (where the wing meets the head) to hide the entry line. I followed the inner line to cut out the drawer block.

Glue-Up: After removing the core, I glued the entry kerf shut. Once sanded, that cut line basically disappears.

Step 6: Hollowing the Drawer

Now I took that solid core block and sliced the front and back off it. Then I cut the "U" shape out of the middle to make it a U-shaped drawer. Then I glued the front and back back on.

Handle: I carved a small, abstract bat-shape from maple and glued it to the front of the drawer.

The Finish (Flocking & Oil)

Flocking

Just like my Jewelry Box project, I flocked the inside of the drawers with black Rayon fibers. It looks like the inside of the Batmobile—sleek and soft.

Oiling

I used Danish Oil. It penetrates deep and hardens in the wood. It made the Walnut go from a dusty grey to a rich, deep chocolate color.

Conclusion

This is a fantastic weekend project. It builds your confidence with the bandsaw and teaches you about curves. Plus, it looks awesome on a desk.

Where does he get those wonderful toys? He builds them in his garage.