Flag Display Case

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My brother blessed me with the honor of making a display case for our Dad’s flag presented at his memorial service for his service in World War II.

I was also given the honor of making both of my parents’ burial urns. For part of Dad’s urn, I used some sugar maple that Dad had cut for firewood, but thought it was too pretty to just burn. He had resawed it with his chainsaw and given us several short pieces for cutting boards to make for his grandkids. There was a little left over that I used for the sides of his urn. I used the left over pieces from the resawn ½-inch sides of the urn to make the plywood for the back of the flag display case.

For the inside ply, I used oak.

I glued the maple ply to the oak ply first. I sandwiched the glue-up between two ¾-inch slabs, and ended up attempting to balance it in the center with all the clamps around it. It was a real fiasco!

For the outside ply, I used the resawn pieces from the sides of the case.

I determined that using the corner of my workbench with cauls would be an easier method to glue the final walnut ply.

To make the routing safer on the frame, I routed the profile before resawing it.

I wedged a 1/8-inch thick piece in the kerf to saw the final side.

I realized after cutting the sides that one side had some bad indentations. I ironed it with a damp presscloth which totally removed the damage.

I used 45-degree angles on the main body where the joints don’t show, but the face frame was made with 22.5-degree angles on the bottom using this protractor jig on the disc sander after cutting on the band saw.

To glue up the case, I made a hinged jig.

And here is the final photo in its new home.

L/W

“Those who would give up essential Liberty, to purchase a little temporary Safety, deserve neither Liberty nor Safety.” Benjamin Franklin

29 Comments

Great looking flag case that has a much more finished look tham most. I like the protractor idea on your disc sander,could you share where you got that Lefty?

woodworking classes, custom furniture maker

Jim,

As for the idea, I guess the Lord gave it to me! I did see an idea for a shooting board that was adjustable between 90 and 45 degrees, but it didn’t include a scale. For the protractor, I just typed in protractor images in the search engine and selected this. I had to split the image to make the scale accurate because of where the pivot point is.

L/W

“Those who would give up essential Liberty, to purchase a little temporary Safety, deserve neither Liberty nor Safety.” Benjamin Franklin

Very nice lefty,
I like that base.

Figuring out how to do something you have never done is what makes a good challenge.

Thanks Bently. I did a bunch of prototypes to come up with the final solution. (A very smart husband gave me a lot of good ideas on how to achieve it.)

L/W

“Those who would give up essential Liberty, to purchase a little temporary Safety, deserve neither Liberty nor Safety.” Benjamin Franklin

Thanks Lefty!

woodworking classes, custom furniture maker

You’re welcome Jim.

L/W

“Those who would give up essential Liberty, to purchase a little temporary Safety, deserve neither Liberty nor Safety.” Benjamin Franklin

Such a wonderful project, well done tribute. Very neat to use the maple to make the plywood.  
Thanks BB1.
L/W

“Those who would give up essential Liberty, to purchase a little temporary Safety, deserve neither Liberty nor Safety.” Benjamin Franklin

Nicely done. A great honor. 

Ryan/// ~sigh~ I blew up another bowl. Moke told me "I made the inside bigger than the outside".

really like your clamping jig!

Nice job.


Petey

Thanks Ryan and Pete.
Pete, I'm still waiting for another reason to use that clamping jig!
L/W

“Those who would give up essential Liberty, to purchase a little temporary Safety, deserve neither Liberty nor Safety.” Benjamin Franklin

L/W- when i get around to it i'll make one or buy one.

I have made a lot of flag cases, closing those joints is hard to do.


Petey

The case is one of the best I’ve seen. Your jigs and techniques are great and thanks for the tip on getting out dents w/the damp cloth and the iron. Will save that one. 

James McIntyre

real nice case LWLL. i love how you did the base. 

working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.

Thanks James and Pottz.  I was pretty pleased with the results . . . even if it took me months to complete, with numerous mock-ups to try out methods and jigs.
L/W

“Those who would give up essential Liberty, to purchase a little temporary Safety, deserve neither Liberty nor Safety.” Benjamin Franklin

Neat project and an equally great write up.

Even if people don't need a flag, many may get inspired by your sanding jig,

clamping clues,

I'm also gobsmacked at how many people still don't know

about the iron/wet rag method... nice subtle toss in info.

Cheap and woodwortking in the same sentenc is an oxymoron!