barb, dont over stress this. i know the importance and you want it to be perfect as i would. just put a tiny shim in the gap with some glue then sand it and no one will ever see it. as for a base, it can be as simple as you wont or as fancy. id go simple as a respect for the flag and what it means myself. nice work girl !😎
working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.
That is a finnicky angle to cut Barb. Probably as prone to some drift/movement as you push through the blade as any cut. Using sandpaper on the fence, or even a clamp to hold the stock as you crosscut. That makes sure it doesn't drift.
Blade is best for a higher count (at least 60 tooth) crosscut blade. I try to use brand new ones when doing these. Sharp carbide is good, dull, not so much, and also pitch can create drag, so old blades can sometimes spoil the work.
Those are my 2 go to tips when cutting these.
For a fix, I'm with Larry, a thin shim, and carefully sand it down, and it will all but disappear.
Bases I also agree with Larry, let the flag do the talking.
Thank you Pottz and GeorgeWest. I think I can shim it cleanly so it will match. Started to get some pieces ready to do so when I had a minor kickback as one of the smaller pieces I was using caught. Wasn't major but decided it was a good stopping point to clean up the shop and decide how best to fill the gap.
One thing that really helped with the bevel cuts (I think that's the right terminology for 45s on an edge?) was to take a sled I wasn't using much and adjust it for bevels. The right panel can slide over (after I adjusted the opening for the knob). Worked great and my joints seem tight. Hopefully will give a good glueup.
Like Pottz and GeorgeWest, I think your planned fix is the way to go.
In your other thread (which I somehow missed), you mentioned adding a drawer. Are you thinking about integrating it into your base? The piece you showed is thick enough to accommodate one.
Ron - thanks. Working on that is today's to-do along with getting the case glued up.
After much going back and forth in my mind, I decided against the drawer as it seemed like it would be so shallow as to not be of much benefit. I may build a separate shadow box if my nephew would like to display any items, or a nice box if he would like a special storage option.
Nice job on the repair. I doubt anyone but you will ever even notice it.
I also think you made the right call about omitting the drawer. I think it would have unbalanced the design too much, making it too bottom-heavy and drawing attention away from what should be the focal point—the flag.
Woodmaster1 - that design is really nice but I wasn't comfortable with my ability to do the 22.5 so decided to go with the other option I found with all 45s. I'm happy with how tight I was able to get the joints. I viewed more YouTube and have a plan for the base that I hope to work on today.
I'm learning a lot in this build. Wanted to add splines to the top angle but couldn't find my poorly made jig (maybe I tossed it?!?). Headed to YouTube for options and ran across this no jig method (see here). Realize there is "extra" material removal but seems to work out fine.
Looks great Barb. No one is ever going to notice the gap in the back. Your splines look great too. Once you get some finish on it, it’ll all blend together nicely.
As for the base, if you oversize it a bit, consider leaving the back side flush to the flag case. Otherwise it ends up with a large open gap between the case and the wall when you set it on a table or in a cabinet. A little detail router work on the sides and leading edge of the base make for a nice contrast as well.
Not that I’d think you’d go this way, but I saw a beautiful case once, made of walnut, with an ogee cut along the oversized base. The ogee was painted black and gave a very stylish accent to the whole thing. I’m not usually a paint & clear finish kind of guy, but that one looked really nice.
Ryan/// ~sigh~ I blew up another bowl. Moke told me "I made the inside bigger than the outside".
Pottz - trying to get better about it, but I still let mistakes get to me. 🤷♀️
Ryan - thanks! I thought I had a base, but messed up the width as I measured using the case BEFORE I attached the face frame. Now if I offset the front, the base isn't supporting the back of the case (and I don't like it flush on the front).
Groan - my last section of that walnut too. 😟 I'm going to try a different design.
If I can't get a final product I like, I'll start over (not what I want to do!). The case part is coming along.
barb-relax girl, dont stress it. your doing fine. nothing wrong with mistakes, each one should teach us something. keep going, it's looking good, seriously !
working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.
