Flag Box #3: 45s, Clamping Blocks and Glue Up

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Blog entry by DBoltz posted 08-27-2012 09:34 PM 7445 reads 3 times favorited 4 comments Add to Favorites Watch
« Part 2: Sanding, Rabbets, Sample Colors, 22.5 Degree Miters Part 3 of Flag Box series Part 4: Time for Splines »

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 can see the parallel surfaces it gives us to attach our clamps. I attached my cutoffs to some thin scrap and then clamp the whole assembly to the side pieces.

And here it is in the clamps. This glue up went pretty smooth. I did a dry fit right before and had all my clamps in place ready to go.

Next time we will get the box out of the clamps, smooth the joints, cut for the corner splines, and install the splines. I went and ordered the nameplate today. I will have that back by next Tuesday.

-- Dan, Virginia Beach

4 comments so far

View DIYaholic's profile


19921 posts in 3964 days

#1 posted 08-28-2012 12:23 AM

This is looking great. Nice documentation of the process.

I need to design and build a flag case for my father’s burial flag. This blog will help immensely. Thanks for sharing. I know it is quite an undertaking to document & blog during a project build. Looking forward to seeing more.

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procrastination a bad thing?

View DBoltz's profile


122 posts in 3668 days

#2 posted 08-28-2012 06:26 PM

Thanks, Randy. Hopefully this does help you. If you have any questions along the way, give me a shout. I’d be happy to help if I can!

-- Dan, Virginia Beach

View AAWW2005's profile


128 posts in 4239 days

#3 posted 08-29-2012 01:01 PM

Looks good Dan, here is a little known fact for ya; there are no 90deg angle star points on the flag. When you cut the top, cut 40’s (80deg) and on the bottom, cut 60’s(120). You’ll get a perfect 1,2,3,4 pattern to the edge of your boxes off the top row of stars. Hope this helps!

-- "Your Design or Mine!"

View DBoltz's profile


122 posts in 3668 days

#4 posted 08-29-2012 01:18 PM

Thanks, AAWW2005. Interesting fact about the star points.

-- Dan, Virginia Beach

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