A couple of weeks ago I was asked how I cut the angles on my flag cases.  Well, today I cut 3 out for my online store so I grabbed a few pictures.  Keep in mind that I”m a big advocate of using a digital protractor so that my 45 degree angles at the top are truly 45 degrees and my 22 1/2 degree cuts on the lower corners are truly 22 1/2 degrees.  I cut these angles with a tenoning jig.  The last picture shows how I join the angled corners.  Filament tape is strong enough to let me pull the joint together.

 

 

Have a tenoning jig just like that!

 

Great process.

54 minutes ago, lew said:

Have a tenoning jig just like that!

 

Great process.

Oldie but a goody

 

Thank you Ron, I greatly appreciate it.  Are you cutting the 45's with the same set up?  Do you have any tips or techniques to ensure you get the exact same lengths?

Cal, I cut both angles with the tenoning jig.  I have a Kreg miter and I set the miter stop at 18 1/2”.  When I locate the sides in the tenoning jig I put the side piece on a piece of 1/4” plywood, check vertical square to the saw top and lock the piece in the jig.  Then I remove the 1/4” plywood just before I cut the piece.  If you look you can see the gap between the saw table and the end of the side piece.

Here are the joints after the glue up.  I didn’t mention it before but I I cut a 1/4” x 1/4” recess on the back for the inset panel before glue up.  I also cut a groove for the glass a shade over 18” and 3/4” from the front edge.  After the glue up I open the groove up from the bottom with a 1/4” spiral up feed router bit.

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So, the hardest part of these cases is the back.  I rout a 1/4” x 1/4” groove and inset a 1/4” thick triangle to retain the flag.  I keep the inset triangle in place with turn buttons.  Cutting the triangle inset can be a challenge because it wants to slide on the saw top and there wasn’t a good way to secure it.  I built a jig to clamp to my miter to hold it. MInhave a piece of double backed carpet tape on the jig and I get perfect cuts now. 

1 minute ago, Ron Dudelston said:

So, the hardest part of these cases is the back.  I rout a 1/4” x 1/4” groove and inset a 1/4” thick triangle to retain the flag.  I keep the inset triangle in place with turn buttons.  Cutting the triangle inset can be a challenge because it wants to slide on the saw top and there wasn’t a good way to secure it.  I built a jig to clamp to my miter to hold it. MInhave a piece of double backed carpet tape on the jig and I get perfect cuts now. 

Great idea, Ron!

Does you saw have a Vega fence?

Looks like the elite Sears fence. I had one and it was hard keep aligned.

14 hours ago, lew said:

Does you saw have a Vega fence?

It sure does.  Good eye.

Good tips.  I got a Vega fence too.  Cost more than the used 113 Craftsman table saw.

2 hours ago, Ron Dudelston said:

It sure does.  Good eye.

 

25 minutes ago, honesttjohn said:

Good tips.  I got a Vega fence too.  Cost more than the used 113 Craftsman table saw.

Did you ever have to replace the glued on tape measure?

Not yet.  Few years old and still still stuck on good.  Fine tuning the adjustment took a little doing though.

4 hours ago, lew said:

 

Did you ever have to replace the glued on tape measure?

Not yet but I have replaced the brass lockdown device.

4 hours ago, honesttjohn said:

Not yet.  Few years old and still still stuck on good.  Fine tuning the adjustment took a little doing though.

I can honestly say that I’ve never used that fine adjustment.  Easier to bump the fence with my hand.

24 minutes ago, Ron Dudelston said:

I can honestly say that I’ve never used that fine adjustment.  Easier to bump the fence with my hand.

Thanks. Sorry to have hi-jacked the post 

2 hours ago, lew said:

Thanks. Sorry to have hi-jacked the post 

You didn’t. More the merrier

Ok, last post.  I built 2 walnut and an oak.  Here’s the oak case.

Nice!