I am building a flag box for the flag from my Father-in-law, Bob’s, funeral. Bob was in the Army during the Korean conflict and recently passed away. This is my third flag box (one is posted under my projects and the other will be posted soon) so I thought I would share my process. My design is based off of Tommy MacDonald’s from an episode of Rough Cut. I like the design because I think the 22.5 degree angles on the bottom are awesome. They aren’t the easiest angles to cut but a good jig helps with that.
This box will be a little different in two ways. First, my trim pieces will be contrasting the main side pieces where as in my other two, I used the same wood for the side pieces and the trim. Also, I will be adding a base which will house the 9 shells from the 3 shot volley from the honor guard.
I will be using walnut and maple for this box. The side pieces are 3” wide which is wide enough to hold the flag, glass, and back pieces. Trim pieces will be roughly 3/8” thick by 1” wide when all is said and done.
Let’s get started:
I start with the side piece and an over sized piece of trim. We will cut the trim to size later.
Here is the trim piece clamped up to the side piece. The side up is the inside piece of the bottom. The trim over hangs the outside by just a little. That will get flushed with the side piece later. Trim is roughly 3/8” thick and will be cut down to about 1” wide later. The trim is decorative and also will hold the glass in place. The side piece is right at 3”. There will be a 1/4” rabbet in the back of all three pieces later to accept the back.
Here is the outside of one of the side pieces. You can see the trim was not flush with the side. I will also fill in/stabilize those voids in the wood with CA glue.
Here is the inside of one of the side pieces. Glue needs to be cleaned up and the side piece sanded.
Next episode will show the trim getting flushed and voids getting filled in.
-- Dan, Virginia Beach