I built a shadow box/flag display case for my grandfather's medals from WW2 and the flag from his funeral. My dad brought me his flag and medals a couple years ago, and this project has been on the to-do list for awhile.
I started by cutting the sides to length and mitering each corner to 45 degrees.
Next I ripped an inch from the sides to make the box top and cut a slot for the front plexiglass to fit into.
Then I clamped it up and let it dry.
Next I started on the main box, which had the added complication of a diagonal piece to separate the flag from the rest of the box.
Once I got the diagonal piece to fit, I cut slots in each to accommodate the backing of the box.
For the backing, I glued some felt to plywood using some spray adhesive.
While the backing dried, I finished up the lid. I wanted to add some splines to the corners to strengthen the joint and add a little flair. I built a simple jig to hold the lid at 45 degrees so I could run it across the table saw and create a 45 degree slot for the splines.
Here you can see a piece of oak in the corner to test the fit.
I originally was going to use some oak scrap, but I wanted more contrast between the spline and main body. I had a small piece of Koa wood that I brought back from Hawaii last year that I thought would be perfect to use for the splines, so I trimmed off a small piece and cut 4 small triangles.
Here you can see a closeup of the spline after I trimmed it down.
After that was done, I cut the excess felt away from the backing pieces...
...and then did a test fit to make sure everything fit together well.
After gluing everything up, sanding, and finishing with danish oil, I added the hinges. Here I started by marking the outline of the hinge with a striking knife.
Then I cut a shallow mortise for the hinge to sit in, using the lines from the striking knife as a guide.
After I finished the hinges, I added a magnetic closure in one corner of the box.
Here you can see the completed box and the splines.
Here's a shot from the top with the lid on.
And here's a clearer shot without the glare from the lid.
The woodworking part is done, but I'm still working on the interior. I need to mount the medals/badges, and I'm planning to get a small plaque made with his name and dates of service. Maybe a picture if I can find a decent one of him in uniform. Not sure if one exists.
Update September 2020
It took awhile to get the medals in from the National Archive, plus covid slowed everything down, but I finally got around to finishing this project up. I got a small plaque with his service dates and mounted everything using epoxy.
Hanging on the wall:
Bonus picture of him in uniform:
