free.woodworking-plans.org Opening: A Patriotic Project Show your American pride and honor the service of loved ones with a handcrafted flag display case. Building your own flag case allows you to personalize the design and create a cherished heirloom. This step-by-step guide provides clear instructions to create a beautiful and respectful display for your treasured flag. Let's get started!
Materials and Tools: Gather Your Supplies Before diving into the project, ensure you have all the necessary materials and tools on hand. This will streamline the building process and prevent unnecessary interruptions.
- Wood: Choose a hardwood like cherry, walnut, or maple for a lasting and elegant look. Pine is a more budget-friendly option. You'll need enough to cut the case sides, top, bottom, and back. Typically, a 1x6 board (actual dimensions are usually 3/4" x 5 1/2") is sufficient, depending on the size of the flag.
- Acrylic/Plexiglass: For the front window of the case. Measure the inside dimensions of the assembled case to determine the size you need.
- Hardware: Hinges (small, decorative hinges work well), a latch or clasp (magnetic or swivel), small nails or brad nails, wood glue, sandpaper (various grits), wood stain or finish of your choice, picture frame hanging hardware.
- Tools: Measuring tape, pencil, saw (miter saw recommended for precise cuts), drill, drill bits, screwdriver, clamps, sander, safety glasses, dust mask.
Step 1: Cut the Wood Carefully measure and cut the wood pieces to the following dimensions. These dimensions are approximate and may need adjustments based on the specific flag you're displaying. Remember, the flag is typically folded into a triangle. The case will have a triangular front. The base is typically 24 to 26 inches, and the height is approximately 12 to 13 inches.
- Sides (2 pieces): These will be angled pieces that form the sides of the triangle. Calculate the angles using online resources or a protractor to ensure a proper 45-degree angle at the top where they meet.
- Bottom (1 piece): This is the base of the triangle. 24-26 inches long, as mentioned above.
- Top (1 piece): This will connect the tops of the side pieces, forming the peak of the triangle. It will be a short piece (usually around 3-4 inches).
- Back (1 piece): Cut this piece to fit snugly inside the assembled case. It should be a rectangle that covers the entire back opening.
Step 2: Assemble the Case Now, it's time to assemble the main structure of the flag case.
- Apply wood glue to the edges where the side pieces meet the bottom piece.
- Clamp the pieces together securely and allow the glue to dry completely according to the manufacturer's instructions.
- Once the glue is dry, reinforce the joints with small nails or brad nails, driven in at an angle for extra strength.
- Attach the top piece in the same manner, using glue and nails. Ensure the angles are correct and the joints are tight.
Step 3: Prepare the Back Panel The back panel will provide support and a surface to secure the flag.
- Ensure the back panel fits snugly inside the assembled case. If necessary, trim it down to size.
- You can attach the flag directly to the back panel using small tacks or staples. Alternatively, consider adding a foam board or felt lining for a softer surface.
Step 4: Sanding and Finishing Sanding and finishing are essential for a professional-looking flag case.
- Sand all surfaces of the case, starting with a coarser grit sandpaper (e.g., 120 grit) and gradually moving to finer grits (e.g., 220 grit, then 320 grit). This will create a smooth surface for finishing.
- Wipe away any sanding dust with a tack cloth.
- Apply your chosen stain or finish according to the manufacturer's instructions. Multiple coats may be necessary for a richer color and better protection. Allow each coat to dry completely before applying the next.
Step 5: Install the Acrylic/Plexiglass Window The acrylic window will protect the flag and provide a clear view.
- Carefully measure and cut the acrylic sheet to fit the opening of the case. You can use a utility knife with multiple passes or a specialized acrylic cutting tool.
- Secure the acrylic sheet to the case using small nails or brad nails, driven in at an angle around the perimeter. You can also use clear silicone sealant to attach the acrylic.
Step 6: Attach Hardware Add hinges and a latch to complete the case.
- Attach the hinges to one side of the case and the corresponding edge of the back panel.
- Install the latch or clasp on the opposite side to secure the case closed.
- Attach picture frame hanging hardware to the back panel for easy display.
Step 7: Final Touches and Flag Placement
- Give the entire case a final inspection and touch up any imperfections.
- Carefully place the folded flag inside the case, ensuring it is centered and properly positioned.
- Secure the back panel in place with screws or nails.
Conclusion: A Lasting Tribute Congratulations! You've successfully built your own flag display case. This handcrafted tribute will serve as a lasting reminder of service and sacrifice. Proudly display your flag and cherish the memories it represents. This project is not only a fulfilling DIY endeavor, but also a meaningful way to honor those who have served.
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