Shopsmith Forums

It’s a good thing I’m working on a prototype! Thank you to whoever it was that suggested that. I made a bunch of cuts on some scrap hardwood pieces so I could see that I was achieving both 22.5 deg and the knife edge. So those are good, but the bottom piece is 3/8” short on the inside dimension. Then my attempt at the top miter ended up a little short (oops). I still have a lot of hours to put into woodworking to get close to the quality I’m hoping for. I don’t think I’m finishing this in time for a Christmas. At least I can have some photos of my progress. I do think this is going to come out very fine, but may take a little while to get there.

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Miters aren't easy.

In some cases I have made jigs . the neat thing about wood working is the creativity . don't be too critical , we all strive for perfection but the trim will cover up some of the inside issues and the out side can be dressed up byu a little sanding and you will be the only one who knows . I found a video that may help in you display box , you may have all ready seen it . https://www.youtube.com/watch?v=CjA7afRebFc

Did you side boards both measure the exact same in length ?

This site has very good plans complete with dimensions for building these cases. I used these plans a few years ago when I made up some cases. They worked out great.
https://www.woodworkersjournal.com/maki ... flag-case/
This is their plans. If you follow it closely, the corners should fit well. These are made from those plans.

On occasion we make picture frames , I lay out the format on a small piece of plywood then use scrap pieces to outline the frame then fit the pieces into the frame , it has helped quite a bit. one thing important is that all the pieces are exactly the same dimensions as far as thickness and width and some times length . I was surprised at how much expansion and contraction do to temp and humidity changes things .

I really appreciate all the suggestions and experience shared here. Early on I decided to go with the design shown in the video found on the Woodworkers Guild of America’s site (link found in my first post, I believe). Although they did not include an actual plan or drawing, I used their methods to draw out my own using the dimensions of the flag that will go in this case. Even though I made my own drawing, including all dimensions, I stupidly forgot that I had the side dimensions and tried their method of cutting the 22.5 deg miters and then laying out the wood to determine the length of the side boards. The problem is holding the parts adequately to mark the upper length of those boards, so when I was making my prototype, I ended up with the gap seen in my last photos. For my cuts on the walnut I used the dimensions from my drawing, and added a little bit. They came out exactly how I had hoped. They are just a bit long, so a little sanding on the conical disk will help me do the final fit. It is coming together after.

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More progress today. I built a temporary fence for my router table, then cut the grooves and rabbets in my prototype pieces, and once it was right I did the same on the walnut. I rounded the front edges, and taped it together to see how it’s come out so far. I’m thinking it might come out OK. There’s still some stages to come where I can screw it up, but I’m hoping for the best.

Here are some photos of the taped together stage.

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It looks like you’re in the home stretch! And man, is that walnut going to pop when you get the finish on it.

Wow you are doing an amazing job. Well done 192.168.1.1
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