For years my saw blades have just been stored on the built-in “storage” bolt sticking out of the side of my table saw. Well, there also have been a few in the plastic tub that my dado stack also lives in. Whenever I needed to switch out the blade it was inevitable that the one I needed for the job was at least the third or fourth blade in the stack of about six or seven. Really not the most efficient or enjoyable thing to have to dig through that pile. Definitely not the best way to store the blades to protect their longevity – especially when I would drop one when taking it off the bolt. That’s a great way to break a saw blade tooth and ruin the blade.

So it was finally time to grow up and build myself a better way to store my saw blades. I drew up these saw blade storage box plans as the inspiration for what I am going to build to store the majority of my saw blades (dado stack not included). I intended the saw blade storage box plans to be simple, but then as I got further into the design I couldn’t help myself but add some finishing touches to hide the majority of the joinery. I should be able to build the majority of this from scrap lumber I still have laying around even after the air compressor cart and Kreg jig station I just built from the scrap pile. The only “new” wood I’m planning on using is the spalted maple I picked up on clearance from the local lumber shop. So much for simple!

Materials Needed / Cut list

• 1 – 12″ x 24″ sheet of 3/4″ plywood
  • cut 2: 11″ x 11 3/8″ sheet of 3/4″ plywood
• 1 – 12″ x 24″ sheet of 1/2″ plywood
  • cut 1: 11 1/2″ x 12″ (top)
  • cut 1: 11 1/4″ x 11 3/8″ (back)
• 1 – 11″ x 10 3/4″ sheet of 1/4″ plywood (bottom)
• 1 – 4′ x 4′ sheet of 1/8″ hardboard
  • cut 15: 11″ x 11″ pieces of 1/8″ hardboard (shelves)
• 15 – 1/2″ x 3/4″ x 11″ pieces of hardwood (shelf fronts)
• 1 – 6″ of 5/8″ diameter dowel
  • cut 15: 3/8″ long pieces (for shelves)
• 2 – 1/2″ x 1/2″ x 11 3/8″ hardwood trim (optional)
• 15 – 1/2″ drawer pull knobs
• 48″ of 1/2″ edge banding (optional)

Tools Needed

• Table saw
• Drill
• Trim nailer
• Wood glue
• CA glue (recommended, but optional)
• Small iron (for the edge banding)
• Edge banding trimmer
• Various clamps are helpful

Step1: Build the shelves

The shelves in these saw blade storage plans are fairly basic. Start by cutting 15 pieces of 11″ x 11″ sheets of hardboard, 15 pieces of 3/8″ long 5/8″ diameter dowel. Start by gluing the dowels onto the hardboard, noting that they are offset 1/8″ from center towards the back. If you opted to use CA glue, this is where you want to use it. It will create an instant bond between the dowel and the hardboard so you don’t have to worry about the dowel sliding while the glue dries.

Next, take your 1/2″ x 3/4″ x 11″ pieces of hardwood and rip a 1/4″ dado 1/8″ from the bottom on the 3/4″ side. Use standard wood to attach the hardboard in this dado. After the glue dries, drill the hole for the drawer pulls and attach them.

Step 2: Cut the sides of the storage box

The sides in these saw blade storage box plans are simple, but complicated at the same time. Remember that you are making two of these sides, and they need to be mirrors of each other, not twins. Starting with your 11″ x 11 3/8″ sheet of 3/4″ plywood, you are going to cut a 1/4″ x 1/4″ dado 1/8″ up from the bottom 11″ edge. Then you’ll need to proceed to cut 14 additional dados, 1/8″ wide x 1/4″ deep, spacing them 5/8″ apart. This should leave 1/2″ at the top after the last dado. NOTE: Cut all of these dados on both sides and the back at the same time so you can ensure they line up.

For the dado on the back edge to slide in the back, you’ll want to pay attention that you are doing mirrored sides. So one piece will need to be rotated clockwise, and the other counter clockwise from your previous cuts. The back is going to require two passes, the first is going to be with the board standing on its back edge, and the blade set at 1/4″ high. Cut a dado 1/2″ in from the outside of the piece. Now, lay it back down and cut a 3/8″ dado inset 1/8″ from the back edge. This should produce a profile as in the second picture below.

Step 3: Cut the back wall

The back wall is made from a 1/2″ sheet of plywood cut to 11 1/4″ wide x 11 3/8″ high. Start by cutting a 1/8″ x 1/8″ rabbet on each side of the outside wall (see second image below). Now flip the piece over and cut a 3/8″ x 1/4″ rabbet on each inside wall side.

You should have already cut the dados in the back wall at the same time you cut them in the side wall, so at this point you should be ready to join the three pieces together using wood glue and clamps. The back wall should fit snuggly into the grooved profile you cut on the side walls so the back edges of the sides are flush with the back wall.

Step 4: Add the bottom

The bottom of this saw blade storage box is made from an 11″ x 10 3/4″ sheet of 1/4″ plywood. Cut a 1/4″ deep x 1/8″ wide rabbet around both sides and the back. You should be able to slide it into the bottom half of the 1/4″ dado on the sides and back. Use wood glue to secure it in place. It is also a good idea to slide the bottom shelf into the top of the 1/4″ dado to ensure the two of them fit in there together. Make certain not to get any glue on the bottom shelf, or it won’t come back out very easily.

Step 5: Add the top and the front trim.

At this point you should be able to slide all of your shelves in place to ensure they fit and slide appropriately. After ensuring everything fits, and is square, it is time to attach the top. If you want to add some edge banding to the top to hide the plywood edges, now is the time to do it. After the banding is added, use wood glue and finish nails to secure the top in place. Lastly, you can add the optional pieces of trim to the sides to hide the dados in the shelves to give it a more finished look. Use wood glue and trim nails to hold them in place.

That’s it, you are done with the construction of these saw blade storage box plans. It is time to add a nice finish of your choosing, then start enjoying it. Since I picked up that spalted maple for the shelf fronts, and my leftover plywood is also maple, I will probably opt for just using a few coats of polycrylic to highlight the natural beauty of the wood.

I hope you enjoy these plans and find them useful. Please check out our other jig and workshop plans. If you have any questions, leave us a comment below. And don’t forget to submit your build if you use these or any of our plans to build something of your own.

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