LumberJocks Woodworking Forum banner
  • Please post in our Community Feedback thread for help with the new forum software! If you are having trouble logging in, please Contact Us for assistance.
1 - 4 of 4 Posts

·
Registered
Joined
·
29 Posts
Discussion Starter · #1 ·
Day 1

OK, so I decided to go with the Flag Display case. Shouldn't take too long, and I really want to protect the flag and memorabilia. I started out with two rough sawn red oak boards that were in pretty bad shape. You can see in the picture that about 1/3 of the boards are splintered pretty bad. I figured that since the parts for this project are pretty small, I could manage to get enough straight grain out of these two boards and save some of the better lumber for other projects.

Rough sawn lumber with layout marks.


Cut down into more manageable chunks.


So I marked out the pieces with chalk to get the best yield from each board, then I used a circular saw to break them down into more manageable chunks. I used the band saw to rip to width. I prefer this method, saves wear and tear on my table saw blade, I also don't have to worry about the wood binding up the table saw or circular saw. To me it just feels safer. I then went to the jointer to flatten one face and one edge. After that, I ripped the pieces to rough width and sent them through the planner. I now have rough milled stock that can sit and move if it needs to. All of the stock is over sized at this point by about a 1/4" in width and thickness, and about an inch longer. That should give me plenty to play with in case the wood does move.

Rough dimensioned lumber, just need to let it move for a couple of days, I did sticker it after this photo was taken.


I still haven't decided on the final size, I am going to build it custom to fit the flag, I don't want the shadow box portion of the display to be too large and overwhelming. I will be building a jig for the acute angles of the lower flag case, I expect it will be a simple jig made out of plywood and scrap pine that will attach to my miter gauge. I probably will make a prototype frame out of some MDF to make sure I get all the dimensions and angles right, and that the scale of the separate pieces works.

I will post more as I make some progress.

Cheers Everyone!
 

·
Registered
Joined
·
18,890 Posts
Day 1

OK, so I decided to go with the Flag Display case. Shouldn't take too long, and I really want to protect the flag and memorabilia. I started out with two rough sawn red oak boards that were in pretty bad shape. You can see in the picture that about 1/3 of the boards are splintered pretty bad. I figured that since the parts for this project are pretty small, I could manage to get enough straight grain out of these two boards and save some of the better lumber for other projects.

Rough sawn lumber with layout marks.


Cut down into more manageable chunks.


So I marked out the pieces with chalk to get the best yield from each board, then I used a circular saw to break them down into more manageable chunks. I used the band saw to rip to width. I prefer this method, saves wear and tear on my table saw blade, I also don't have to worry about the wood binding up the table saw or circular saw. To me it just feels safer. I then went to the jointer to flatten one face and one edge. After that, I ripped the pieces to rough width and sent them through the planner. I now have rough milled stock that can sit and move if it needs to. All of the stock is over sized at this point by about a 1/4" in width and thickness, and about an inch longer. That should give me plenty to play with in case the wood does move.

Rough dimensioned lumber, just need to let it move for a couple of days, I did sticker it after this photo was taken.


I still haven't decided on the final size, I am going to build it custom to fit the flag, I don't want the shadow box portion of the display to be too large and overwhelming. I will be building a jig for the acute angles of the lower flag case, I expect it will be a simple jig made out of plywood and scrap pine that will attach to my miter gauge. I probably will make a prototype frame out of some MDF to make sure I get all the dimensions and angles right, and that the scale of the separate pieces works.

I will post more as I make some progress.

Cheers Everyone!
great step by step.
 

·
Registered
Joined
·
29 Posts
Discussion Starter · #3 ·
Day 2

I didn't feel much like going to work today, so I took the day off. I did some odd jobs around the house and managed to carve out some time to work on this project. I looked at all of the rough milled wood, didn't bend or twist a bit. So I played it safe and ran it all across the jointer, through the planer to final thickness and then ripped it to final width.

I made some prototype case pieces out of cherry scraps I had, and worked out the flag case size. I built a jig to cut the lower flag case miters. I kept it simple, a piece of 3/4 plywood with a 45 degree cut across one end. I glued and nailed a 3 1/2" piece of pine so I could clamp it to the miter gauge. Another strip of pine glued and nailed to the 45 and I had myself a jig. I tried to cut the cherry without the piece of pine on the 45, but found I couldn't accurately cut the case pieces. I really needed something I could clamp the pieces to to make sure they stayed 90 degrees to the table, and didn't move side to side.

Here is a picture of the final jig, I know it is ugly, but it worked and kept my fingers away from the blade!



Here is a picture of the jig with a case piece clamped in



I was pretty happy with the results of the jig. I will probably hang it on the wall, never know when you might need it again!

After cutting all of the case pieces to length, I started gluing them up. First, two corners of the shadow box. Once they dried, I clamped the two halves together to make the frame. Made sure everything was square, and set it aside to dry.

Two corners glued



Shadow box glued and clamped



After that, it was time to assemble the flag case, this proved to be pretty interesting due to the 22.5 degree miters. I cut 4 cauls at 22.5 degrees and glued on some sand paper. I clamped the two blocks together to form a V, then I placed them over the two corners and put a clamp between them and it pulled everything nice and tight.

Flag case glued and clamped



While the cases were cooking, I started on the face frame, originally I had the face frame about 1 1/4" wide and 3/8" thick. After laying a molding piece on the prototype case, I found it to be too wide and it really cut down the view of the flag. I ended up at 1" for the width and kept the 3/8" thickness. A simple bead on one side and a chamfer on the other.

Molding profile



I cut all of my moldings so that I had about 1/16" of an inch overhang on all sides. I glued them up separately, and once everything had set for a couple of hours, I glued the moldings in place on both cases.

While the assemblies were cooking, I made a 3/8" spacer to separate the two cases, I didn't want them to be directly butted up against each other, I thought it added a little visual interest to the piece.

That is as far as I got today, next time I will be sanding and fitting the backs. I may even get the glass for the cases tomorrow if I have time.

I'll leave you with a look of where the project is right now, once sanded, I can attach the two cases together and think about finish.

This picture is just one sitting on top of the other. I guess this is a bad camera angle since it looks kind of miss shapen.



Cheers!
 

·
Registered
Joined
·
2 Posts
Day 2

I didn't feel much like going to work today, so I took the day off. I did some odd jobs around the house and managed to carve out some time to work on this project. I looked at all of the rough milled wood, didn't bend or twist a bit. So I played it safe and ran it all across the jointer, through the planer to final thickness and then ripped it to final width.

I made some prototype case pieces out of cherry scraps I had, and worked out the flag case size. I built a jig to cut the lower flag case miters. I kept it simple, a piece of 3/4 plywood with a 45 degree cut across one end. I glued and nailed a 3 1/2" piece of pine so I could clamp it to the miter gauge. Another strip of pine glued and nailed to the 45 and I had myself a jig. I tried to cut the cherry without the piece of pine on the 45, but found I couldn't accurately cut the case pieces. I really needed something I could clamp the pieces to to make sure they stayed 90 degrees to the table, and didn't move side to side.

Here is a picture of the final jig, I know it is ugly, but it worked and kept my fingers away from the blade!



Here is a picture of the jig with a case piece clamped in



I was pretty happy with the results of the jig. I will probably hang it on the wall, never know when you might need it again!

After cutting all of the case pieces to length, I started gluing them up. First, two corners of the shadow box. Once they dried, I clamped the two halves together to make the frame. Made sure everything was square, and set it aside to dry.

Two corners glued



Shadow box glued and clamped



After that, it was time to assemble the flag case, this proved to be pretty interesting due to the 22.5 degree miters. I cut 4 cauls at 22.5 degrees and glued on some sand paper. I clamped the two blocks together to form a V, then I placed them over the two corners and put a clamp between them and it pulled everything nice and tight.

Flag case glued and clamped



While the cases were cooking, I started on the face frame, originally I had the face frame about 1 1/4" wide and 3/8" thick. After laying a molding piece on the prototype case, I found it to be too wide and it really cut down the view of the flag. I ended up at 1" for the width and kept the 3/8" thickness. A simple bead on one side and a chamfer on the other.

Molding profile



I cut all of my moldings so that I had about 1/16" of an inch overhang on all sides. I glued them up separately, and once everything had set for a couple of hours, I glued the moldings in place on both cases.

While the assemblies were cooking, I made a 3/8" spacer to separate the two cases, I didn't want them to be directly butted up against each other, I thought it added a little visual interest to the piece.

That is as far as I got today, next time I will be sanding and fitting the backs. I may even get the glass for the cases tomorrow if I have time.

I'll leave you with a look of where the project is right now, once sanded, I can attach the two cases together and think about finish.

This picture is just one sitting on top of the other. I guess this is a bad camera angle since it looks kind of miss shapen.



Cheers!
Looking good my brother! Now get some pics up of that new shop of yours.
 
1 - 4 of 4 Posts
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top