I made this box for a U.S. Army Soldier as a go away gift. In the lid, the black area is a cork board covered with black felt, so the Soldier can put their awards/ribbons. It took me around 2-3 weeks to get it done (waiting for paint dry and polyurethane to cure and then assembly).
Dimension for this box are 18"L x 10"W x 12"T and includes the following:
Main Box Body
1. Cut 2 Pieces of pine wood for the front and back section with the following measurements (18"L x 9"T) and 2 for the sides (10"W x 9"T)
2. Stain your cut pieces as desired. In this case I left it natural color with torched edges.
3. Add whatever design you want, in this case I made a carving that was later hand painted.
4. Decide on how to assemble the box. I used Half bind dove tails, it provides a strong bond.
5. Cut a 3/4" deep x 1/4" wide groove for the base plate. I use a wood glue/finish nails combination to be in the safe side.
1. Cut 2 pieces of pine wood for the front and back section with the following measurements (18"L x 3"T) and 2 for the sides (10"W x 3"T)
2. Add a design or leave empty to the top part of the lid.
3. Conduct steps 4 & 5 for the lid part.
4. Before gluing everything together, create a grove all around the inside of the lid (table saw blade width and no more than 1/8" deep). This grove is where you will put the plexy glass that covers the flag.
5. Cut the final piece to complete the flag case. I don't have specific measurements, since I do it by eye.
6. Add cork to the area next to the flag, you can use Elmer's glue for this process. and cover the cork with black felt.
7. Fold a flag (3x5) with dignity and respect, mine are all folded by a U.S. Veteran.
1. Cut 2 pieces of pine wood for the front and back section with the following measurements ( 16 1/4"L x 2"T) and 2 for the sides ( 9 3/16"L x 2"T)
2. This is not an item for heavy objects, so I do not to dove tails on the tray.
3. Cut a 1/4" Deep x 1/4" wide groove so you can add a 1/4" piece of wood as a base.
4. Once tray is assemble, add to the box body a stopper, so the tray sticks out a little bit and doesn't go all the way inside the box.
1. Using a 1/4" roundover bit, trim the edges to give it a more clean look (Box, lid and tray)
2. re-stain the areas that you just trimmed. In my case, I torched those edges
3. Apply polyurethane for the desired finish. I personally use the 3X poly.
4. Once everything has cured, add all the desired hardware ( Chest latches, Chest Handles and decorative hinges)