Decide on which size of flag you will be building a flag display case (fdc) for.
3'x5', 4'x6', 5'x9' (burial)
Measure the folded flag. For this example we will use the 5x9 burial flag.
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You will need the bottom (horizontal) measurement,
along with the two diagonal measurements. Also get
the thickness of the folded flag.
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* bottom msmt: 24"
* diagonal msmt: 16 3/4 "
* thickness: 2 3/4 "
Decide on the type of wood you will be using, for this example, we will use oak.
A 1x4 piece of oak actually measures 3 1/2 in
width, which is fine. Buy an 8' length. (for be-
ginners, in case there are mistakes)
Seeing that our flag is triangular in shape, we will
cut the angles on a 45 degree. You can do this with a
circular saw or a chop saw (mitre saw). Chop saws
give a much better cut.
The bottom measurement of our flag is 24". So our
inside measurement of our 45 degree cuts must be
at least 24". I recommend cutting the length of board at 24 1/4"
(little play room for glass and flag)
You should have approx. 6' of board left. As you know,
wood has a grain pattern. These next steps will give your case
a more professional appearance.
Measure off the longest portion of the angled 6' board
(that's your long point of that particular angle, the
other is the short point of that particular angle.)
Your angled measurements are 16 3/4".short point
to short point. However, you will be cutting it 3"
longer than that, (for mistakes). So let's just cut
our side pieces 20" long. short to short.
Measure off the 6' board from long point 20", using a
speed square or framing square, make a mark and cut
your piece. (set this piece aside)
The longer remaining piece should have a short point.
Your objective now is to turn that piece around 180
degrees, and cut the short point again in order to
make it a long point.
Once you do this, your two 45 degree angles at the top
of the display case will fit and the grain will match.
It will look continuous. (match up all the angled
pieces until you find that grain match)
When you place the bottom piece up to the angled side
pieces to form the triangle you will notice that the
side pieces are too long. Just pencil mark the bottom
where it hangs over the bottom piece. That now is going
to be cut at a 45 degree. Make sure you cut the 45
degree angle the correct way. Your end product should
be a short to short angled piece.
When you are marking the piece to be cut, also mark
the side of the board so you know for sure, which way
the wood should be cut.
Tack the frame together or use a strap to hold it in
position.
Measure the size of glass you will need.
We can measure the glass in two ways:
(1) -The exact size, minus 1/8th inch. (if you are going
to place a wooden corner cover over the glass and
attach it to the frame.) OR
(2) - The glass can be measured 1/4" larger if it is going to be inserted into the frame.
Buy an 8' piece of wooden corner board.
(for outside corners of walls) It is 3/4" long on each
side of the 45 degree angle. Cut this to fit the
outside (facing) of the triangular frame you just made.
You can insert the glass from the back side after the
outside wooden corner's are nailed on. Then you can cut and place 3
pieces of 1/4 "x 1/4" molding on the inside to hold
the glass in place.
Inset glass involves using a table saw.
Set your table saw guide to 1/4" from the inside of the saw blade to the guide itself.
Set the depth of the blade to 1/8th inch.
-- If you know at the beginning that you will be insetting the glass, then cut the entire 8' length of board at one time. It's very difficult to cut small pieces like this and have it turn out correctly.
-- If you have never used a table saw, ask someone with experience to perform this next step.---
Take the piece or pieces and with the table saw in operation, slowly guide the piece along the guide, making sure not too force the cut. Be gentle. It's wise to use a forked stick to push the wood through the cutting process.
There are jigs that can be purchased for just this job. Call a do-it-yourself place. They can help you
Once you have your cuts made, you are ready to nail it together.
Use small trim nails (1 1/4") long and nail frame together. With glass inserted into the cut grooves you just made.(Set nails with punch and color putty when done)
This is much easier if you have a brad gun. also place the frame so the glass is face down so it doesn't break if it falls out during this process.
Take the frame and place it on some 3/16th luon (lew-on or oak paneling)
and trace the outside of your frame. Cut this out for the backing of your display case. (Stain edges with the proper color. For oak, you can use Minwax-Colonial Maple or Early American.)
You can drill about 8 pilot holes through the 3/16" luon into the wood frame. (On the Back Side) for screws. Insert your burial flag. Insert your screws.
--That's a rap folks--your project is done.
***Read everything, before you try anything***
Tools & Supplies
* Tape
* Pencil
* Circular Saw
* Speed Square (or)Framing Square.
* Sand Paper.
* Stain,Putty andPolyurethane
* Chop Saw (Mitre Saw)
* Cut Glass
* 2' x 2' piece of Oak or Maple paneling 3/16 or 1/4" thick.
* Sponge or Brush.
* 3/4" screws (8-10ea)
* Small box of 1 1/4" trim nails. Or 1 1/2".
* 8'- 1x4 board. (For your fdc frame.)
* 8' Wooden (Outside corner board). 3/4"
* Safety Glasses!
***WARNING***
* The 1st time you
disrespect a Power tool, IT WILL disrespect YOU!
* If you have children
around, during the
building and cutting
process be sure to
UNPLUG POWER to all your tools until you use them again. Then, unplug them
again!
TIPS:
Don't be in a rush. You can do this.
When ever you take a measurement add 1/16" to it. (20 1/16" instead of 20") That way, you cut ON the line and you will always have the true measurement that you need.
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