How to Build a Memorial Flag Display Case

hey guys my name is Aaron Massey and today I'm going to show you how to build a memorial flag display case Father's Day is right around the corner and my dad is extremely hard to shop for I never know what to get him he's kind of the guy that has everything doesn't need anything and never ask for anything about a year ago my dad lost his father who was a World War 2 veteran he passed away at the age of 89 at his funeral my dad was given the flag that draped over my grandfather's casket and so for Father's Day this year I figured I would build him a memorial flag display case for my grandfather's flag I did a little research online and found that all burial flags are the same size they're five feet by nine and a half feet and I was able to find a set of plans online on the woodworkers journal that actually has a pretty detailed breakdown of how to build the case which I'm going to be kind of following and modifying so that I can make it kind of my own so I'll put a link in the description below where you guys can find these plans if you want to follow along I'm going to be building this case out of some beautiful walnut I found at my local lumber store so to get started I'm going to rip some 3-inch strips of the walnut on the table saw that are going to act as the back of our case I need to cut some of the walnut pieces at 22 and 1/2 degrees to create the mitered corners and I don't really have a way to do this safely or easily my chop saw can't cut that and my table saw also can't cut that safely so I'm going to be building a basic tenant in jig for my table saw so that I can keep my hands free and clear and it can support the walnut pieces so they can stand up vertically so I can cut the 22 and 1/2 degree angle not going to go into a great amount of detail as to how I'm building this tenoning jig for the sake of time in this video the idea is that it's a 90 degree angle it holds a piece of wood so that it can stand vertically and it allows you to make more acute angles than you normally could on your table saw before I make any of the mitered cuts in the walnut' I'm going to use a piece of scrap wood and do some test cuts just to make sure that everything works properly next I can cut the pieces for the body of the case according to the sizes from the plan the bottom piece is mitered at 22 and 1/2 degrees on each end while the two side pieces are mitered at 22 and 1/2 degrees on the bottom and 45 degrees at the top here's what it looks like put together before I glue it up I'm using my dado stack to cut an eighth inch deep by quarter inch wide rabbet in the back of each piece this will allow me to put my back panel on later to glue up the body I'm using some rapid views and a strap clamp to hold everything together nice and tight and while that sets up I can work on the face frame I'm modifying the plans at this point because I'm going to make the case hinged on the face whereas the plans are for a fixed face frame I have to turn the face frame pieces on the jig to cut the miters which doesn't allow from my blade to pass all the way through so I trim the remaining with my trim saw and clean up the edges with the sander I'm carving a rabbit on the inside edge of each piece so that the glass will inset into the face frame later on then using my palm router I'm adding a little bit of detail on the inside face of each piece this is where a router table would really come in handy but I haven't built or bought one yet so I'm doing this by hand which isn't as precise but I'm not really one to let the tools that I have stopped me from doing something so I'm making it work from there I can glue up the face frame next I can lay out and Mark where I'm going to be chiseling out some hinge mortises on the case body and chisel them out and then I can lay out and chisel the corresponding hinge mortises on the face frame and pre-drill and attach the face frame to the case body next I hit the hole case with some hundred and twenty grit sandpaper on the orbital sander to clean up any imperfections and then work my way up to 220 grit paper by hand i pre-drilled a 3/8 hole in both the face frame and the case body and epoxy two couple rare earth magnets in the holes to act as a latch to keep the case closed with the case sanded down to 220 grit I'm going to apply the first of three coats of tung oil finish let it dry and then sand it again at 500 grit add another layer of tung oil finish sand it once again at 600 grit and then add a third layer of tung oil finish but the backing of the case I'm just using a piece of hardboard so I measure how big the piece needs to be and then I cut it out with my utility knife and then I pre-drilled and installed the backing with some small brass screws lastly I brought the case into a glass shop and had them cut a custom sized piece of glass for the case ended up costing me $7 so it's not very expensive to install the glass I'm running a thin bead of silicone all the way around and then holding it in place with a few retaining clips well here it is guys the finished memorial flag case I'm really happy with the way that it came out is it perfect no it's not perfect but I'm pretty damn proud of it since I don't have my grandfather's flag i mocked up a smaller flag in the case so that you guys can kind of see what it's going to look like once the flag is in it I'd like to extend a very special thank you to our veterans and active duty military personnel thank you guys so much for what you do if you like this video please hit that like button and leave a comment down below thank you guys so much for watching and I'll see you next time hey guys my name is Aaron Massey today I'm going to show you how to build some super simple DIY triangle shells

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