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Flag Box

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Blog series by DBoltz updated 09-07-2012 11:31 AM 6 parts 11795 reads 10 comments total

Part 1: Gluing up the trim

08-22-2012 08:36 PM by DBoltz | 4 comments »

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...

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Part 2: Sanding, Rabbets, Sample Colors, 22.5 Degree Miters

08-26-2012 01:42 AM by DBoltz | 0 comments »

Since we left off last time, I got the voids in the wood filled in with CA glue and the boards are sanded to 150 grit so far. I used my block plane to get the trim close to the side pieces. My FIL did not have much in the way of woodworking tools. He did have a Skil 1/4 sheet sander. My MIL wanted me to have it. I thought it would be appropriate to use that sander on his flag box. You can see the sander in the background here. Sanded to 150 grit here. Here you can see the trim c...

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Part 3: 45s, Clamping Blocks and Glue Up

08-27-2012 09:34 PM by DBoltz | 4 comments »

We finished the 22.5 degree cuts last time. This time, we tackled the 45s and got the case glued up. Cutting the 45s on my crosscut sled. A little blue painter’s tape helps support the fibers of the maple. I’ve never used it before but I did not want to take any chances with the figured maple. Cuts came out smooth. Like the 22.5s, I slowly crept up on the final size. Here are a couple of photos of my 22.5 degree clamping blocks. This is why we saved those cutoffs. You...

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Part 4: Time for Splines

08-29-2012 06:12 PM by DBoltz | 1 comment »

We’ve got the box out of the clamps and smoothed out. Time to cut the splines. I have a spline cutting jig I made for my table saw. It has a saddle that rides along the fence similar to the 22.5 cutting jig. I do the top corners first to get them out of the way. The top corner, since the angles are 45 degrees, just sits in the jig normal. On the 22.5 cuts, I used one of my test pieces of pine to support the angle. You can see that in the picture. I also raised the saw blade a ...

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Part 5: Base

09-03-2012 07:50 PM by DBoltz | 0 comments »

Last time we got the splines installed and flushed up. Now, we will get the base done. Mortises cut on the base and on the bottom of the flag box using your standard drill press and chisel combo. Here we have the majority of the waste of a mortise hogged out using a forstner bit on the drill press. I just used a handheld drill on the bottom of the flag box. Here you can see the supports with the top tenon. They are just dry in the base with the mortise and tenon. I have the layou...

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Part 6: Finished!

09-07-2012 11:31 AM by DBoltz | 1 comment »

Finally got it finished! Got the back cut. 1/4” plywood attached with 7 brass screws. And the name plate is attached. The engraving shop (Village Engraver, Fairfield Shopping Center, Virginia Beach) provided the double sided tape. The box and base are finished with three coats of Watco Semi-Gloss lacquer. I did a light sanding of 320 grit in between coats. After the lacquer dried, I applied some clear paste wax with 0000 steel wool and buffed. I did this twice. The third ...

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