LumberJocks

Hole in One Shadow Box

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Project by jfk4032 posted 10-05-2019 02:22 PM 314 views 2 times favorited 4 comments Add to Favorites Watch

With the exception of a pen I made for myself after I had already made them for my son and his girlfriend and I liked it so much I wanted one too (https://www.lumberjocks.com/projects/243786), I don’t make projects just for me…making them for family and friends is so much more fulfilling. But in this case I was self-indulgent!

After 40+ years of playing golf I finally had my first hole in one on a trip to Hawaii. The kind folks at Poipu Bay Golf Club gave me a flagstick flag for the accomplishment and I knew that day I was going to make something with that. I stashed the golf ball I used for the ace aside and same with the scorecard.

The flag was pretty large and I had to think about how to consolidate the other pieces into a reasonable arrangement that wasn’t honking big. After playing around with several layouts I figured it out and how much room was there for a small engraved plaque which I filled with the leftover space from the other fixed sized pieces.

With a base of just under two feet by two feet, I didn’t want a solid piece of wood/plywood as it would be really heavy. For the base, I came up with a sandwich of .25” plywood and .5” foamcore and then glued on a black walnut veneer surface on the top show side. I tested how deep I could inset the golf ball into this sandwich without it poking through the underside. I made several test holes into .75” plywood on my CNC to very precise diameters to seat the ball just right. I set the ball in from the topside and used a few blobs of hot glue from the underside to secure it in place. I kept the dirt/grass marks on the ball so a piece of Kauai is still in the arrangement.

I had a constraint on my miter sled of 2.375” high to cut the frame corners in one single cut. This also meant I had to make sure the golf ball didn’t stick up too high to fit underneath the inset plexiglass and the .75” rabbit to fit over and hide the base and keep that all within 2.375” frame height for the miter cuts. I tested the frame profile on some leftover pine and I got everything to just fit. I milled some black walnut to match test profiles and those frame blanks were ready to miter cut for a perfect fit. I cut the miters and glued 3 sides together leaving the topside unattached. I wound up epoxying in the plexiglass to the slot on the topside frame piece and then attached that to the rest of the frame with two countersunk brass screws. So, in case I need to get inside the frame I don’t need to take the backside fully apart. Now I can just unscrew the top and slide off the plexiglass with that frame piece.

I played around cutting sheets of brass on my CNC and then engraving them previously. Having a printer’s background I am well versed in graphics software and I was able to perfectly replicate the Poipu Bay logo and logotype for the plaque. The cutting and engraving went well and I just had to debur the sharp edges, buff and apply brass lacquer to it and it looks totally professional. I used brass screws to attach it.

I had to create a scorecard holder and came up with a simple three sided black walnut frame with a slight rabbit on the underneath side to fit the edges of two thicknesses of scorecards. The original scorecard is underneath out of view and the top scorecard which is less worn with better penmanship used! I used brass screws to attach it.

With the flag I used adhesive backed velcro to attach it. When testing this, and keeping the flag taught as I could, the adhesive didn’t stick well to the nylon flag. So, I cut new pieces and used two part epoxy to attach the fabric velcro piece to the flag and it held well and allowed me to pull the four corners to keep the flag pretty flat.

I finished all of the black walnut pieces and veneer with satin lacquer sprayed with my HVLP unit. I bought a framer’s staple gun earlier this year to fix a broken piece of glass in a picture of ours and this was the perfect time to use that to secure the base into the frame. That’s it until the next project.

-- ---Joel; Central MD...rookie empter nester and getting back into woodworking!





4 comments so far

View Peteybadboy's profile

Peteybadboy

1288 posts in 2488 days


#1 posted 10-05-2019 05:57 PM

Nice job on the box! Welcome to The HIO club. I had my first this year as well. One guy at our club has 12!

-- Petey

View luv2learn's profile

luv2learn

2978 posts in 2842 days


#2 posted 10-05-2019 09:25 PM

Congrats on the hole in one Joel. You have done a remarkable job in displaying your accomplishment!!

-- Lee - Northern idaho~"If the women don't find you handsome, at least they ought to find you handy"~ Red Green

View shipwright's profile

shipwright

8399 posts in 3337 days


#3 posted 10-06-2019 02:42 AM

Nice display.
I hope you got to see yours. Mine was at an elevated green.

-- Paul M ..............the early bird may get the worm but it’s the second mouse that gets the cheese! http://thecanadianschooloffrenchmarquetry.com/

View LittleBlackDuck's profile

LittleBlackDuck

3015 posts in 1360 days


#4 posted 10-06-2019 07:59 AM

Great memento jfk’... however, how about a close up of the score card… after all, that could be any golf ball… and of course we would all trust the card!

-- If your first cut is too short... Take the second cut from the longer end... LBD

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