This project was built and designed by Sam Macy. It’s a meaningful woodworking project that serves as a beautiful tribute to someone who has served in the military.
A shadow box like this is a timeless way to preserve and display an American flag along with medals, ribbons, and other memorabilia. Whether made as a gift or a personal keepsake, it’s a project that carries deep emotional value.
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Why a Shadow Box Matters
A military shadow box does more than just hold a folded flag. It represents a legacy of service and offers a way to showcase the milestones of someone’s time in uniform.
These boxes are often passed down through families, becoming heirlooms that tell a story through carefully preserved details. It’s a project that’s both practical and symbolic.
Selecting and Preparing the Wood
Sam begins the build by choosing walnut, a hardwood known for its strength and rich appearance. S4S lumber is used to save time on milling, which makes it easier to get right to the cutting stage.
The frame of the shadow box is made from three triangular sides. These are cut to rough length first, then brought to final width using the table saw to ensure clean, straight edges.
Making the Stoppers
To hold the glass and flag in place, Sam creates small quarter-inch strips. These keeps, or stoppers, are cut using double-sided tape to hold the thin pieces against a larger backing board.
This technique prevents the narrow strips from vibrating or kicking back during cutting. It’s a simple trick that adds precision and safety to the process.
Shaping the Frame
After the pieces are dimensioned, Sam adds a thirty-degree bevel to the front edges. This angle creates a clean, polished profile for the shadow box when viewed from the front.
He then uses a dado stack to cut a groove inside the frame. This dado gives the flag a pocket to sit in while also concealing its edges for a professional finish.
Gluing the Triangle
With the grooves and bevels complete, it’s time to assemble the triangular frame. Spring clamps are used to hold the joints tight while the glue sets, keeping everything aligned.
Sam checks for flush edges at every corner, ensuring a seamless fit. Any misalignment could throw off the appearance or make installing the glass more difficult.
Sanding and Finishing the Frame
Once the glue has dried, the frame is sanded thoroughly. Sam sands all surfaces up to 400 grit for a smooth, touchable finish.
The dust is removed with mineral spirits, which also reveals any remaining scratches or glue spots. For the final finish, Sam applies botanical polymerized tongue oil to highlight the walnut’s color and grain.
Building the Base
To complete the display, Sam builds a matching base for the shadow box. The base is cut with a complementary thirty-degree bevel to match the angle of the triangular frame.
This creates a consistent reveal across the top, giving the finished piece a polished, intentional look. Using the same species of wood also helps everything feel cohesive.
Installing the Glass and Back
Once the triangle and base are complete, it’s time to add the glass. Sam measures the opening directly to ensure the glass fits snugly.
The keeps created earlier are used to hold the glass in place, secured with small nails. This method keeps the glass removable in case it ever needs to be replaced.
A backing board is cut and installed to enclose the display. Picture frame clips are added to secure the back and make future access simple.
Final Assembly
With the structure complete, the folded flag is carefully inserted into the shadow box. The fit is checked to ensure it’s snug, clean, and well-centered.
When mounted on the base, the entire piece becomes a strong visual statement. It’s functional, beautiful, and built to last.
A Lasting Tribute
A shadow box like this is more than just a woodworking project. It’s a deeply personal item that holds emotional value for families and veterans alike.
Building one offers the chance to create something that truly honors a life of service. It’s a project that reminds us of what woodworking can mean beyond just the materials.
Want to See the Full Build?
Please support Sam by visiting his website here: https://sammacydesigns.com/