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Making Flag Boxes for America's Heros


Cross-cutting the selected grain pattern off a 12 footer soft maple

For the 2 Flag boxes I picked Maple, 1 board mostly clear, the other marbled with heartwood. Each has its unique beauty.

The goal will be to cut them and join them right at the cut line so it looks like 1 continous board wrapped in a triangle. And in fact it is. This will be the top point.

Checking for fine scratchs or natural voids.

Easily filled with a quality maple filler, looks exactly like the natural pinkish, very beautiful, maple flecks.

This board had a bow or crown. To straighten, held in a jig to cut the crown. The blade is just beginning to cut into the crown. Feather board & splitter make it safe

Cutting a slot that will secure the trianglar glass

Feather boards holding down & in for perfectly parallel slot with uniform height. Safer too!

Push stick keeps hands safe

Just how I want it - perfect!

Similar setup for cutting the edge rabbet, for the back door to the box. Dado blade is partially buried in the fence for complete & chip free cut.

Rabbets in center, slots on outside edges. Georgeous wood, love it.

Lookin good. Time to cut the 22 & 45 degree miters

1st plan out the cut markings (alphanumerics on left) and cutting order, avoids mistakes

Mark it on workpiece to keep track of things

Square up a reference edge, layout from here for 1st cut

1st cut marked on tape. Tape will help prevent chipout. Line on tape to verify setup

Setup for 45 degree cut, it must be perfect
America's Heros, We Thank You . . . . . . . . . . . . . www.ValRoseWoodWorks.com