A Flag Display Box #9: The Final Details Begin...

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Blog entry by littlecope posted 03-12-2010 02:29 AM 1173 reads 1 time favorited 12 comments Add to Favorites Watch
« Part 8: Of Windows and a Parting of the Ways... Part 9 of A Flag Display Box series Part 10: Hinge Pinning and a Latch »

The finish line is in sight, but there’s still a few details to cross off the list. I left off here a few days ago, sides up and pinned, “Glass” in place: After Pinning Corners
Yesterday, I took a few minutes to cut off the excess finger joint material. Some people wondered why I left them over-long… They helped me out through out this build and now are helping me one last time. I cut half-way through one side…Removing Over-long "Fingers"
Then cut all the way through the second side…Removing Over-long "Fingers" - #2
Then complete the first cut.Removing Over-long "Fingers" - #3
That took about two minutes, but all told, after filing, cleaning, and sanding, it mushroomed to about a half hour…
My attention again turned to the hinges. Some of you may have noticed I didn’t pre-drill them this time… but I’m going to do it now! I started, as always, by scoring marks with an awl to start the drill in the correct location:Marking for Drilling
I’m going to be using 1/4” Dowels to attach these, but I’m going to build up to that size, starting first with an 1/8” drill.Preliminary, smaller holes
Then I’ll move up to a 7/32” drill. This is to ease the stress of drilling large holes through such a small piece!Enlarging the holes
I’m going to stop there. The final sizing holes will be drilled when the hinges are glued to the box… Which is the next step!
I wondered about this next step considerably, how to hold the whole Flag Box upside-down or point side down, with no large bench vise, while I glued on the hinges…
But I had an idea…An idea is born
After adding a couple Clamps, by gum, it looks like this is going to work!!Clamped up
I don’t need or want a “death grip” on these clamps, just enough to keep everything nicely lined up. Using my handy-dandy “Custom” Spacer Block positioned to the bottom of the tenons, the glue-up was quickly achieved…Hinges glued on
And now I wait for glue to dry… I’ll have all night and all of my work day tomorrow to agonize over whether I’ll have shaky hands when I hand drill the final holes for the pins… :)

-- Mike in Concord, NH---Unpleasant tasks are simply worthy challenges to improve skills.

12 comments so far

View ellen35's profile


2734 posts in 3395 days

#1 posted 03-12-2010 02:36 AM

It looks like you are nearly done. I am so pleased to see your “signature hinges” are a part of this loving project!
Looking forward to seeing the final product.

-- "Don't let the perfect be the enemy of the good." Voltaire

View oluf's profile


260 posts in 3002 days

#2 posted 03-12-2010 02:42 AM

Are you going to make saw cuts in the ends of your pins before you install them? That way you can drive small wedges into them to lock them in place. Sand them off flush and they will look very nice.

-- Nils, So. Central MI. Wood is honest.Take the effort to understand what it has to tell you before you try to change it.

View Dan'um Style's profile

Dan'um Style

14171 posts in 3945 days

#3 posted 03-12-2010 03:24 AM

aw you’ll do alright … got confidence in ya buddy ! >grin< looks really good

-- keeping myself entertained ... Humor and fun lubricate the brain

View bigike's profile


4050 posts in 3251 days

#4 posted 03-12-2010 03:27 AM

very nice work! love the hinges

-- Ike, Big Daddies Woodshop,

View littlecope's profile


3071 posts in 3465 days

#5 posted 03-12-2010 03:44 AM

Ellen: Yes, sadly this project is winding down… I had to go back and check; this was begun 38 days ago and though I’ve dragged my feet unmercifully, the actual work time on this is only about 18 hours. As I keep on saying, I’ve been pretty busy… I’m in gear now though, and ready to finish it and move on!!
oluf: Nils, using Fox or Blind Wedges is a good idea, and I’ve done it before, but for these I’ll just put a spot of glue in the hole and tap them in. The fit is pretty tight, so I don’t really foresee a problem. This is a box which won’t see much use, at least in the way of a normal box; being open and shut all the time…
Dan: Thanks, my Friend! Your confidence in me is inspirational… I only wish I had that same confidence!!
bigike: Thanks to you as well, Ike!!

-- Mike in Concord, NH---Unpleasant tasks are simply worthy challenges to improve skills.

View Kristoffer's profile


675 posts in 3179 days

#6 posted 03-12-2010 06:28 AM

Mike, it’s looking great. And as for your comment TO Dan…. Shut up and have the confidence! What are a couple holes compared to the things that you have done?! Your hinges are awesome and you do good work! Now, all it comes down to is balls-out confidence. You can do it, so just do it.
The only reason I put it that way is because I’ve found myself pacing and wondering if I can actually continue with my vision of a project or if I bit off more than I can chew. And almost every time, it woks out the way I hoped. But, only after I tell myself to “quit being a synonym for cat AND JUST DO IT!” So, go for it!!!

-- Cheers and God Bless

View Bob Kollman's profile

Bob Kollman

1798 posts in 3153 days

#7 posted 03-12-2010 08:21 AM

Looks good Mike. You don’t mean hand drill like the wood wright shop do you???
All drills should use an electrical power source!!!

-- Bob Kenosha Wi.

View stefang's profile


15881 posts in 3297 days

#8 posted 03-12-2010 10:23 AM

I think the whole project has been interesting and fun to watch Mike, but the hinge part is the thriller here, so I am eagerly awaiting the attachment of them and the latch.

Talking about drilling for those dowels I find it strange that if I use a brad point wood bit, the dowel hole turns out just a bit too roomy while the regular twist drill leaves a more snug fit. Are you aware of this, and if so do you know why that is?

-- Mike, an American living in Norway.

View littlecope's profile


3071 posts in 3465 days

#9 posted 03-12-2010 11:45 AM

Kristoffer: Well alright!! With Dan’s inspiration and your scolding, I guess I’ll proceed!! :)
Bob K.: I have a couple of egg beater type drills but won’t be using them for this! Those take two hands to operate… I’d need a third hand to hold the work! I was talking about my antique electric hand drill…
Stefang: Mike, I only own one Brad Point Bit, so I’m hardly an expert. I can tell you that I stopped using it for 3/8” holes for pins a while ago because the holes end up too big… If anybody knows why, I’d be interested too…

-- Mike in Concord, NH---Unpleasant tasks are simply worthy challenges to improve skills.

View Jason's profile


659 posts in 3471 days

#10 posted 03-12-2010 05:46 PM

Looking good Mike. About drilling the pins, don’t think just do.

Question: In the 8th pic with the case upside down in the milk crate there appears to be a hammer hanging upside down to the right. What is the purpose of this? Just being nosy. Thanks.

-- Jason - Colorado Springs

View Kristoffer's profile


675 posts in 3179 days

#11 posted 03-12-2010 11:54 PM

I hope that you know that I meant no harm. I just hate it when I look back and think about the times that I have doubted myself…. For so many reasons.
Can’t wait to see it all come together.

-- Cheers and God Bless

View patron's profile


13600 posts in 3304 days

#12 posted 03-13-2010 12:05 AM

i couldn’t figure why you left the fingers so long ,
now i just remember that you make ’ shims ’ ,
from them for the slight gaps in the joinery .

this is excellent , mike . a wonderful tribute !

well done .

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

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