Looking for a heartfelt DIY project to honor a loved one? Anthony and Bob Barker from Wood Pack DIY created a beautiful memorial flag display case, perfect for showcasing the service flags of veterans.
Materials and Tools Required
- Walnut boards
- Plexiglass
- Thin plywood for the back
- Wood glue
- Wood filler
- Finish (e.g., charcuterie board finish)
- Clamps
- Router
- Table saw
- Track saw or crosscut sled
- Measuring tape
- Chisel
- Sanding tools
Step 1: Preparing the Wood
To start, Anthony cut the walnut boards down to size, making 45-degree cuts on each piece to join them together. He then adjusted them to the desired thickness using a table saw. Once the boards were sized, he measured and created a groove for the plexiglass front.
Step 2: Creating the Plexiglass Groove
Using the table saw, Anthony ran the boards through to create a groove for the plexiglass. However, he realized he cut through the bottom without a miter, which would require a little wood filler later.
Step 3: Assembling the Frame
To hold the 45-degree mitered corners together, Anthony used wooden call pieces, clamping them in place while the glue dried. Meanwhile, he cut the plexiglass using a track saw for a straight edge and tested the fit.
Step 4: Adding the Back Panel
Next, Anthony used a router to create a groove for a thin plywood back. He had to do some chisel work to get into the corners properly. For the top part, he simply chiseled out a square corner to fit the wood snugly.
Step 5: Sanding and Finishing
After assembling the frame, Anthony sanded down the edges and rounded the corners for a polished look. He then cut the back piece from a leftover thin plywood sheet, ensuring it fit snugly.
Step 6: Applying the Finish
For the finish, Anthony used the same product he applied on his charcuterie boards, which provided a lovely appearance. He mentioned that applying the finish after assembly made cleanup around the plexiglass a bit more challenging.
Step 7: Inserting the Flag
Once the finish dried, Anthony peeled back the protective covering from the plexiglass edges and inserted the flag into the case. He placed the back panel into position, which fit snugly without the need for additional hardware.
Conclusion
Both flag display cases turned out well, with the second one being easier due to the planning involved. This project serves as a great way to display and honor military service flags and can be adapted for various shadow box projects.