Spring has sprung. Get out and shoot your Henry
Memorial Flag Box Project
- BrokenolMarine
- Ranch Foreman
- Posts: 5854
- Joined: Sat Nov 26, 2016 8:28 am
- Location: South Central Oklahoma in the mountains
Memorial Flag Box Project
I started the Flag Box project yesterday, by working on the formal layout. I don't usually do a full size drawing, unless it's for a special project like this one.
First I chose the ones I did have in the proper lengths based on color and grain patterns. There is plenty of wood left if I make a mistake or three. To get the second longer wide board, I first matched a couple of the longer 3" boards for color, then jointed the edges. Once I got a good match, I test clamped them to insure a gap free joint, then glued and clamped them to insure a good bond.
This will be the bottom panel of the two panel base. You may remember from an earlier post, that I took measurements off the actual flag, and created a substitute out of cardboard and sent the real flag HOME with the owner. I didn't want to risk it. The box will be built around this cardboard stand-in. Watch this space.... for updates.
I got out into the shop this morning and went through the mahogany pile and chose the various boards I needed, after going over the drawing and taking careful measurements to determine which boards I'd need in which lengths. I have two widths available, 3" and 3-3/4. Unfortunately, I needed two of the wider ones in the longer lengths, and wasn't going to have but one at that length... so it required some work.First I chose the ones I did have in the proper lengths based on color and grain patterns. There is plenty of wood left if I make a mistake or three. To get the second longer wide board, I first matched a couple of the longer 3" boards for color, then jointed the edges. Once I got a good match, I test clamped them to insure a gap free joint, then glued and clamped them to insure a good bond.
This will be the bottom panel of the two panel base. You may remember from an earlier post, that I took measurements off the actual flag, and created a substitute out of cardboard and sent the real flag HOME with the owner. I didn't want to risk it. The box will be built around this cardboard stand-in. Watch this space.... for updates.
1 x
You can tell a lot about the character of a man...
by the way he treats those who can do nothing for him.
by the way he treats those who can do nothing for him.
Re: Memorial Flag Box Project
Very cool stuff BoM.
Curious about the bubble gum in the second pic, or is that for you?
Curious about the bubble gum in the second pic, or is that for you?
1 x
- BrokenolMarine
- Ranch Foreman
- Posts: 5854
- Joined: Sat Nov 26, 2016 8:28 am
- Location: South Central Oklahoma in the mountains
Re: Memorial Flag Box Project
I allow myself one piece while working in the shop. I don't have any in the house.Henry88 wrote:Very cool stuff BoM.
Curious about the bubble gum in the second pic, or is that for you?
I lost thirty pounds a couple years ago, and am trying to keep it off. Lol.
1 x
You can tell a lot about the character of a man...
by the way he treats those who can do nothing for him.
by the way he treats those who can do nothing for him.
- BrokenolMarine
- Ranch Foreman
- Posts: 5854
- Joined: Sat Nov 26, 2016 8:28 am
- Location: South Central Oklahoma in the mountains
Re: Memorial Flag Box Project
Work session yesterday got me started on the upper section of the flag box, working from the notated sketch using the measurements noted.
The upper "flag box" was cut yesterday. Turned out okay. I set up the miter saw on the mobile cart so it's right in the work area. Makes things much easier. Will get back at it this morning, after coffee is done. Can't work without coffee.
My plan is to cut out all the sections I can up front, and do the basic sanding. Then work on the accents and the additional necessary tooling, such as the dado at the back for the rear panel. Then mark all the fitting, and drill the needed holes for assembly. I plan to have what screws will be used hidden. The holes will have to be marked and drilled before any assembly begins.The upper "flag box" was cut yesterday. Turned out okay. I set up the miter saw on the mobile cart so it's right in the work area. Makes things much easier. Will get back at it this morning, after coffee is done. Can't work without coffee.
0 x
You can tell a lot about the character of a man...
by the way he treats those who can do nothing for him.
by the way he treats those who can do nothing for him.
- BrokenolMarine
- Ranch Foreman
- Posts: 5854
- Joined: Sat Nov 26, 2016 8:28 am
- Location: South Central Oklahoma in the mountains
back at it
Back at it this morning... still working on the basic cutting and fitting... NO gluing up.
I started by cutting out the basic components of the base. The face and sides, and the first level of the bottom. All the accents will be routed before assembly. I haven't used the router table in about five years, but I think I will use it here for consistency in this project.
Next I took the clamps off the lower wide glue up jointed base panel and trimmed it to size. First I had to use one of the cabinet scrapers to remove the glue lines and smooth the surface. I saved the scapings to fill in any needed holes or gaps down the road. Assures a good match.
The mock up of the base! Next task was using the strips I cut from the Off Cuts from the base to cut the trim that will hold the glass in the flag compartment. I used the Veritas trim saw and free hand cut the angles after carefully marking them using the flag compartment as my guide.
I cut the bottom trim first, then clamped IT in place, cut the right side angled trim, clamped it in place.... and then fit the last trim piece ... NOT perfect, but saw dust will fill the small gaps nicely. Next up?
Routing....
Sanding... (LOTS of sanding.. 200, 400, 600 grits)
Beading... not with beads but accent work on the wood.
Still to come?
I'll mark the various locations where holes will be needed, and drill them on the drill press.
I also have to mark the location of the Challenge coins and drill the cavities with the Forstner bits, and drill the pilot holes for the name plate nails.
We are moving right along.
I started by cutting out the basic components of the base. The face and sides, and the first level of the bottom. All the accents will be routed before assembly. I haven't used the router table in about five years, but I think I will use it here for consistency in this project.
Next I took the clamps off the lower wide glue up jointed base panel and trimmed it to size. First I had to use one of the cabinet scrapers to remove the glue lines and smooth the surface. I saved the scapings to fill in any needed holes or gaps down the road. Assures a good match.
The mock up of the base! Next task was using the strips I cut from the Off Cuts from the base to cut the trim that will hold the glass in the flag compartment. I used the Veritas trim saw and free hand cut the angles after carefully marking them using the flag compartment as my guide.
I cut the bottom trim first, then clamped IT in place, cut the right side angled trim, clamped it in place.... and then fit the last trim piece ... NOT perfect, but saw dust will fill the small gaps nicely. Next up?
Routing....
Sanding... (LOTS of sanding.. 200, 400, 600 grits)
Beading... not with beads but accent work on the wood.
Still to come?
I'll mark the various locations where holes will be needed, and drill them on the drill press.
I also have to mark the location of the Challenge coins and drill the cavities with the Forstner bits, and drill the pilot holes for the name plate nails.
We are moving right along.
1 x
You can tell a lot about the character of a man...
by the way he treats those who can do nothing for him.
by the way he treats those who can do nothing for him.
- BrokenolMarine
- Ranch Foreman
- Posts: 5854
- Joined: Sat Nov 26, 2016 8:28 am
- Location: South Central Oklahoma in the mountains
Re: Memorial Flag Box Project
Sheesh... could have sworn I took some pictures of the late afternoon session... but the camera card was empty. I got out for a short forty five minutes. I marked each piece of the flag section in blue chalk, or light pencil marks on the inside as to it's position in the build. Left, right, bottom etc... that way I know the orientation. Then I put a short blue chalk stripe down each edge that needs to be routed BEFORE I took the pieces out of their mock up positions. I did this with the components for the base as well. It's easy to get turned around and mess up a piece by routing an incorrect edge. Sure, I have MORE mahogany, but each of these pieces was chosen for color and grain, especially the three key visual pieces, the two sides to the flag assembly and the FACE plate of the base. The grain and color of those was special, and I don't think I could replace it from the wood I have stacked on the side bench.
I'll take my time, THINK about each piece in my hand BEFORE routing, and look at the markings again to insure they are clear before I even set UP the router table. Better to take extra prep time than to rush it... and ruin a piece. Not as big a deal when I'm making a box just to be filling time and get out of the recliner.... but an important piece like this... an "Honor" piece? Check it twice.
I'll check each piece and make sure all the markings are clear.
"Don't Ask Me How I Know This!"
A common running joke when sharing advice on the woodworking forums... abbreviated DAMHIKT.... We have all made our shared mistakes at least once.... and work hard NOT to make the same one TWICE.
I'll take my time, THINK about each piece in my hand BEFORE routing, and look at the markings again to insure they are clear before I even set UP the router table. Better to take extra prep time than to rush it... and ruin a piece. Not as big a deal when I'm making a box just to be filling time and get out of the recliner.... but an important piece like this... an "Honor" piece? Check it twice.
I'll check each piece and make sure all the markings are clear.
"Don't Ask Me How I Know This!"
A common running joke when sharing advice on the woodworking forums... abbreviated DAMHIKT.... We have all made our shared mistakes at least once.... and work hard NOT to make the same one TWICE.
0 x
You can tell a lot about the character of a man...
by the way he treats those who can do nothing for him.
by the way he treats those who can do nothing for him.
- BrokenolMarine
- Ranch Foreman
- Posts: 5854
- Joined: Sat Nov 26, 2016 8:28 am
- Location: South Central Oklahoma in the mountains
Router Work
I was back at it this morning.... and before I started the work, I made sure that all the markings were clear. Blue Chalk saves things.
I used a 1/4" roundover bit on the lines marked in this picture.
I also marked the edges on the base, but they will be routed with a different bit. The base was routed with a Roman Ogee The Flag was brought by this morning, and checked for fit prior to my routing anything. It fits. Keep in mind that there will be glass in the frame, the trim pieces will be set back 1/4 to 3/8" and there will be a back plate behind the flag... it will fit nicely right up against the glass when all is said and done. Also, this is a rough fit for testing, the edges WILL line up during final assembly. I showed the daughter of the vet what the layout of the face would look like with the coins and the engraved plate. Out of respect I have blacked out the engraving on the plate as it had name and DOB on it. Note that the coins will be inlaid in the face. Here is the base after routing... now the sanding begins ... Lot's of sanding... then assembly. I may also flock the inside of the flag compartment.
As you can see in this pic, as I explained in the earlier post, each piece is identified, and then each edge that will get attention in routing, is marked.I used a 1/4" roundover bit on the lines marked in this picture.
I also marked the edges on the base, but they will be routed with a different bit. The base was routed with a Roman Ogee The Flag was brought by this morning, and checked for fit prior to my routing anything. It fits. Keep in mind that there will be glass in the frame, the trim pieces will be set back 1/4 to 3/8" and there will be a back plate behind the flag... it will fit nicely right up against the glass when all is said and done. Also, this is a rough fit for testing, the edges WILL line up during final assembly. I showed the daughter of the vet what the layout of the face would look like with the coins and the engraved plate. Out of respect I have blacked out the engraving on the plate as it had name and DOB on it. Note that the coins will be inlaid in the face. Here is the base after routing... now the sanding begins ... Lot's of sanding... then assembly. I may also flock the inside of the flag compartment.
1 x
You can tell a lot about the character of a man...
by the way he treats those who can do nothing for him.
by the way he treats those who can do nothing for him.
- BrokenolMarine
- Ranch Foreman
- Posts: 5854
- Joined: Sat Nov 26, 2016 8:28 am
- Location: South Central Oklahoma in the mountains
panel dadoes
Shop work this morning would seem like a lot of time expended for so little result.
I spent about 90 minutes in the shop, with two pictures to show the work completed. Before I started sanding, I wanted to cut the dadoes for the two back panels. The one for the flag panel will be removable, even though I suspect that it will be installed and not come back off unless someone breaks the glass.
The second will be glued and pinned in place and NOT be removed again. The time expended was mostly spend changing to the Box Joint dado blade, setting up the depth of cut and then setting the fence spacing for the Flag box panels and making those cuts, two of which were simple passes, and the base was a stop cut pass which required the panel to be lowered to the blade and moved back and forth to stop lines. (Not a problem with a shallow cut in straight grained knotless woods.) Still, care must be taken and safety gear worn, which I do anyway.
Then, the depth of cut was checked again, and the fence reset for the two cuts for the base pieces, and those two SHORT cuts made. Once those were done, I had to remove the dado blade and reinstall the standard blade. As you can see in the first pic, I will need to use a chisel to finish the cut (dado) in the base of the flag compartment as the drop pass leaves a curve in the dado. No matter. The box dado blade sure leaves a crisp groove huh? Sanding begins after lunch.
I spent about 90 minutes in the shop, with two pictures to show the work completed. Before I started sanding, I wanted to cut the dadoes for the two back panels. The one for the flag panel will be removable, even though I suspect that it will be installed and not come back off unless someone breaks the glass.
The second will be glued and pinned in place and NOT be removed again. The time expended was mostly spend changing to the Box Joint dado blade, setting up the depth of cut and then setting the fence spacing for the Flag box panels and making those cuts, two of which were simple passes, and the base was a stop cut pass which required the panel to be lowered to the blade and moved back and forth to stop lines. (Not a problem with a shallow cut in straight grained knotless woods.) Still, care must be taken and safety gear worn, which I do anyway.
Then, the depth of cut was checked again, and the fence reset for the two cuts for the base pieces, and those two SHORT cuts made. Once those were done, I had to remove the dado blade and reinstall the standard blade. As you can see in the first pic, I will need to use a chisel to finish the cut (dado) in the base of the flag compartment as the drop pass leaves a curve in the dado. No matter. The box dado blade sure leaves a crisp groove huh? Sanding begins after lunch.
0 x
You can tell a lot about the character of a man...
by the way he treats those who can do nothing for him.
by the way he treats those who can do nothing for him.
- BrokenolMarine
- Ranch Foreman
- Posts: 5854
- Joined: Sat Nov 26, 2016 8:28 am
- Location: South Central Oklahoma in the mountains
detail work
Back at it this morning... and decided to knock out some of the detail work. First up... cutting the chisel work on the flag box dadoes for the back panel.
Marked the proper angles after carefully measuring where they needed to be... and got busy. I used two sharp chisels and the mallet, and had to use the Optvisor to see well enough to get the job done. Old eyes. After about an hour of prep work and chisels, it looks pretty good. A little trimming.... and we'll be there. Next, I made up the back for the pedestal. I used some maple ply rather than the thin backer I plan to use for the flag compartment, for strength. I also added some "mini studs." Overkill? Nah, they are placed where I'll be seating the coins, and nailing in the tacks for the faceplate. Okay... overkill. But they were made from scraps and they will help insure the strength of the pedestal and keep it square during glue up. At least that's the plan... and I have plenty of time. I'll get this glued up after lunch, maybe.
Then... sanding.
Marked the proper angles after carefully measuring where they needed to be... and got busy. I used two sharp chisels and the mallet, and had to use the Optvisor to see well enough to get the job done. Old eyes. After about an hour of prep work and chisels, it looks pretty good. A little trimming.... and we'll be there. Next, I made up the back for the pedestal. I used some maple ply rather than the thin backer I plan to use for the flag compartment, for strength. I also added some "mini studs." Overkill? Nah, they are placed where I'll be seating the coins, and nailing in the tacks for the faceplate. Okay... overkill. But they were made from scraps and they will help insure the strength of the pedestal and keep it square during glue up. At least that's the plan... and I have plenty of time. I'll get this glued up after lunch, maybe.
Then... sanding.
1 x
You can tell a lot about the character of a man...
by the way he treats those who can do nothing for him.
by the way he treats those who can do nothing for him.
- RetiredSeabee
- Administrator
- Posts: 2321
- Joined: Mon Mar 21, 2016 5:04 pm
- Location: Harrisburg, North Carolina
Re: Memorial Flag Box Project
Looking forward to seeing this one progress. I saw a lot of flag boxes through the years when I wore the uniform. Some really nice, some good, some not so good. This one is looking incredibly nice.
1 x
Load on Sunday and Shoot all Week.......okay it's a Mare's Leg I will reload on Wednesday.