3'x5', 4'x6', 5'x9' (burial).

Measure the folded flag. For this example we will use the 5x9 burial flag.You will need the bottom (horizontal) measurement, along with the two diagonal measurements. Also get the thickness of the folded flag. * 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 cases 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.

7(1) 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.

7(2): 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 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" into the wood frame. (On the Back Side) for screws.Insert your burial flag. Insert your screws.

Thats 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 and Polyurethane* 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 childrenaround, during the building and cutting process be sure toUNPLUG 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.

Copyright 2007 - Military Flag Display Case - Richard Blodgett - All Rights Reserved.