Sunday, September 23, 2018

Halloween Skull Box Free Scroll Saw Pattern.

Making boxes on the scroll saw is fun because they can be any shape. Halloween is just around the corner so I thought a Skull box was in order. 
 If you are not familiar with scroll saw boxes this how they are made. 
 The inner and outer walls are cut from a single thick board. You cut the center out.
Next, you cut the inner wall and finally, you cut the outer wall. The depth of the box in determined by the thickness of this board. I used a 1" thick board for this box.

You want to be careful when you are cutting the walls that your cut is 90 degrees to the table. If not then the box will not open and close easily. 

Some scrollers have a hard time cutting thicker boards without the blade flexing and making uneven cuts. Make sure your blade tension in tight and let the blade do the cutting without forcing the cut.

One last tip for cutting the walls. Use a #5 or larger blade when cutting the inner wall free from the outer wall. The kerf created between the inner and outer wall determines how easily the box opens and closes. A #5 gives you a snug fit. A #7 is a little looser. Remember that you will probably add finish to the box which will take up some of the kerf you create with the blade.
 When making a scroll saw box it is common to sand the wall flush with the top and bottom after assembly. Because of the irregular shape, this will be a challenge with this pattern. You need to cut accurately so the pieces fit together with little sanding.

I am stack cutting the top and bottom so they are identical. 

To cut accurate you need to learn to cut on the line, just inside the line or just outside the line. To make all the pieces fit you need to use the same method for each piece. If you cut the top and bottom on the line then you need to cut the outer wall on the line. It won't be perfect but with practice, you can get very close. 
When this box was finished I did very little sanding. It fit pretty well. If you look close at the first picture you will see a small ledge between the top and outside wall. This could be sanded away but for a box like this no one will care. It's close enough.

$12 per sheet of 12 coins plus $3.50 shipping
Inlay with a 1" Forstner Bit.
The perfect way to sign your work.

The Shop Stool I use:

Currently $62.89 with free shipping on Amazon.
This is the best price I have seen for these stools.

I have two of these craftsman stools. I am very pleased with their reliability and comfort. I can't stand for long periods of time so I need a tall stool at my scroll saws. I can't sit for long periods on a stool that is not comfortable. Getting older has not been friendly to my back and legs. The stool I use matters.

My scroll saws are all on the manufacturers stands. These stands are designed so you can stand up and cut. I like the manufacturers stands because they do a good job of reducing vibration. That means I need a stool tall enough to put me at the correct height for scrolling.

This stool is adjustable between 28.5 and 33 inches. For me this is perfect. The adjustable hydraulic jack has been reliable. I'm not a small guy and I can kill a cheap stool quickly if they are not made well. This one has held up. I think I bought the first stool about ten years ago. It shows some signs of wear on the cushion but still functions well. The second one is around five years old and is still like new other than being covered in sawdust.

One last tip. If you use a footswitch with your scroll saw you will probably need to elevate it off the ground if you use this stool. I have my foot switch on a wood box about 6 or 7 inches off the ground. My legs are long so you will need to adjust depending on your height.

My only disappointment with this stool is that it does not have casters. On one of my stools, I built a base and added casters. It works but I used small casters and they have trouble rolling over larger wood chips. Large casters make the stool too high. 

If you are looking for a decent quality shop stool I can recommend this one without hesitation. 

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Products for your consideration:

Scroll Saw Pattern Design Tutorial: DVD
Let me teach you to create a beautiful wooden portrait pattern. I will show you everything you need from start to finish. The video will show you the free software program you can download for Windows or Mac OS. I will show you how to install the program and configure it for best results. 
Then I will show you the technique to take your photograph and make a pattern from it. When the pattern is complete we will go in the shop and cut it.
The DVD is $10 plus shipping. This is a data DVD that you will use on your computer to watch the video tutorial  

Every Scrollsaw Workshop Pattern from 2007-2017 in DVD
Purchase the entire Scrollsaw Workshop pattern catalog for offline access.

This DVD has 2,300 patterns published from 2007 thru 2017.
The DVD is $20 plus shipping. Ships to 60 countries around the world.

If you use the DVD on a Windows PC there is a simple viewer program to browse through the patterns.

The DVD also works fine on a MAC. The viewer program is not MAC compatible but there is an included PDF with all the patterns shown as thumbnails for easy viewing. 

Unique Wooden Vases:
Want to create beautiful wooden vases on the scroll saw?
My two "Wooden Vases on the Scroll Saw" books make it easy.

The books are $12 each and available for instant download after purchase. Click for Video Demonstration.

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Bear Woods has been around since 1987 serving our hobby.