For Veterans Day 2024, a friend is making an illuminated acrylic American flag to give away to a veteran in a free drawing. I was asked to donate the frame, and was happy to do so. The frame is made of black walnut.
First the stock is milled to final dimension and mitered.
Next, a relief is routed into the back side of the frame to house the LED control box and IR sensor.
Dominos are added to the mitered corners.
A groove is routed in the top rail of the frame to accept a 24″ aluminum t-track which will allow this heavy piece to be hung from standard No. 8 pan head screws, with flexible spacing.
A hole is drilled and a shallow mortise is cut for the IR sensor.
Next, grooves are cut in the back of the frame to house the 1/2″ acrylic flag, LED strips, and retention frame.
The frame is glued up.
A retention frame is made which will nest into the 3/8″ recess in the back of the frame to hold the acrylic flag in place.
Half lap joints are cut on the table saw sled to join the retention frame together.
After beveling the edges, the frame is finished with clear satin lacquer.
A shipping crate is constructed.
Thanks for your interest.