Osborne Builder's Studio: American Flag Display Case

Start by cutting all 5/4 Lumber boards down to lengths that are manageable for passing through a planer. The boards making up the flag case will eventually be 18”, 18”, and 25”, so aim for a rough length slightly greater than that.

Using a planer, mill the boards down to a thickness of ¾“.

Cut each of these boards to a width of 3½”.

Next, trim the edges of these boards down to their respective lengths. The bottom board will be 25” while the two other boards will each be 18”, meeting at a 45° angle at the peak.

Using a table saw, create ¼” x ¼” channels on both sides of each board. These will fit the acrylic pane and case back later, and may require some adjustments to completely clear out the channel.

Using any available lumber greater than 10” in length, create a sleeve that comfortably fits around and slides along your table saw fence. It should have three sides to it.

Next, you will create a vertical fence for your jig. Simply cut out a board that will be tall enough to support your working material and won’t move during the cutting process.

Drill these pieces together while taking extra caution to use a right-angle reference tool for accuracy.

1. We also recommend adding a second vertical fence on the close end of your jig that will help square your boards even further. You may want to make a reference cut on the jig fence before adding your working material.

2. (Optional): Depending on your clamps at home, you may also need to drill a hole in your jig that allows for it to reach your working material.

Using a digital angle gauge, adjust your saw blade to measure a 22.5° angle.

Using the jig if necessary, cut a 22.5° angle onto one respective end of each of your 18” boards, as well as each end of your 25” bottom board.

Next, using a miter saw, cut a 45° angle onto the remaining ends of your 18” boards, creating the 90° peak.

Using wood glue and a tight strap clamp, combine these three boards together and leave them to dry.

To create the face frame, plane three more of your 5/4 Lumber down to 1” thickness, with the edge grain facing outwards. This frame shares dimensions with the rest of the case, so cut each of them to 18”, 18”, and 25” as well.

To match the base, cut the corresponding 22.5° and 45° angles into your face frame components as well.

Glue and clamp these components together. Leave to dry.

Sand both the base and face frame to get rid of any unwanted glue squeeze-out.

Using your router table, create a channel on your two 18” boards with a 1/32” depth and a width that corresponds with your selected inlay strip. Osborne’s American Flag Inlay Strips have a width of 11/32”.

Cut your inlay strips to 18” and install with limited amounts of glue to avoid squeeze-out. Clamp and leave to dry.

You may use either ¼” Acrylic or glass to fit the display case. If you do not have the resources to cut glass, many glass shops can cut it for a small fee.

Once you verify that your acrylic/glass panel fits, carefully glue it between the face frame and main case. Once again, use a limited amount of glue to avoid squeeze-out, as it may stain your acrylic. Clamp and leave to dry.

With your ¼” Plywood, cut out the backing to the same size as the acrylic using a band saw, miter saw, or table saw.

Sand the case to 150 grit and apply any finish of your choice to both the case and backing. Be sure to use painter’s tape to mask your acrylic/glass panel to avoid staining it.

Once satisfied with your backing’s fit against the case, install 9 or more Picture Frame Turn Buttons to secure it in place. Be sure to use a smaller drillbit when setting these up, as your screws will be quite small as well.

Finally, place your desired flag within the case before securing your backing.