Flag Case Update

[Ron Dudelston]

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.

 

 

[lew]

Have a tenoning jig just like that!

 

Great process.

[Ron Dudelston]

54 minutes ago, lew said:

Have a tenoning jig just like that!

 

Great process.

Oldie but a goody

 

[Cal]

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?

[Ron Dudelston]

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.

[Ron Dudelston]

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.

,

[Ron Dudelston]

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. 

[lew]

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!

[lew]

Does you saw have a Vega fence?

[Gerald]

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

[Ron Dudelston]

14 hours ago, lew said:

Does you saw have a Vega fence?

It sure does.  Good eye.

[honesttjohn]

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

[lew]

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?

[honesttjohn]

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

[Ron Dudelston]

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.

[Ron Dudelston]

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.

[lew]

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 

[Ron Dudelston]

2 hours ago, lew said:

Thanks. Sorry to have hi-jacked the post 

You didn’t. More the merrier

[Ron Dudelston]

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

[lew]

Nice!