Before attempting to build a flag display case the first consideration must be the size of the flag that you want to display. The next thing that has to be decided on is what kind of wood to use, and the last consideration is whether to use glass or plastic to complete the flag display case.
Step 1, Folding the Flag
The United States flag is folded in a very unique way, with each fold representing an aspect of our country’s ideals and symbolism. When the flag is correctly folded it will be in the form of a triangle with approximately seven stars showing on a blue background. Don’t forget to include the thickness of the folded triangle when taking measurements for the display case. The flag display case will be built around this triangle.
Step 2, Measure and Cut Display Case Frame
Begin by cutting three pieces of hardwood to the appropriate sizes forming a frame around the flag. Miter each end of the three pieces to form a neat triangle. Apply a thin bead of glue on each mitered end of the hardwood pieces and apply making tape to hold them together. While the glue is drying, drill a small hole, about the size of the small finishing nails, into each frame corner. Gently tap a finishing nail into this hole to secure each of the triangle ends.
Step 3, Apply Backing and Glass
Secure the flag display case in a wood vise. Begin by using a router and a rabbet bit to router out a groove on each side of the triangular display case frame. The backing will fit within the back of this frame and the glass will slide into the groove in the front of the frame. Place the display case frame on top of a sheet of quarter inch thick plywood, and then carefully outline the frame. Cut the plywood to the line and carefully fit into the back of the triangle frame. Do the same with a piece of glass or Plexiglas.
Step 4, Secure Backing and Glass
Cut out thin strips of hardwood to fit within the grooves made by the router bit. For the backing, apply a thin bead of glue between the frame and the strips of glue. With the finishing nails, nail these strips in place to secure the backing. For the glass front, apply a thin bead of silicone adhesive around the edges of the glass, and then carefully fit in the strips of wood. These should not require nailing.
Step 4, Final Finishing Steps
Sand all wooden parts beginning with 100 and working up to 220 grit sandpaper. Wipe with a dry cloth and apply several coats of varnish, being careful to avoid the glass front.