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How They're Made

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Step One

Select A Flag or Fabric

Pick a flag or fabric that has color and meaning.  Remember, it's labor intensive to make so pick something lasting. 

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Step Two

Fuse the flag to plywood under vacuum

Be sure to use a high grade plywood like baltic birch with epoxy and vacuum for 24 hours.  

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Step Three

Slice in French Cleats

Plan your cuts to incorporate the 45 degree angle for French Cleats. 

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Step Four

Assemble the bottom layer under vacuum

Use epoxy under vacuum to ensure it will be perfectly flat.  

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Step Five

Lacquer spray 20-30 layers

Lacquer spray many coats and level sanding in between to achieve a perfect flat surface.  

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Step Six

Sand and polish to an extreme level

Sand to 3k grit then compound and polish from coarse, fine to ultra fine.  

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Step Seven

Assemble the layers

Very carefully, assemble the layers with epoxy and screws.  Remember, any scratches will be almost impossible to remove once assembled.  

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Step Eight

Select the wood and build the frame

I prefer floating frames but it's dealers choice. 

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Step Nine

Final assembly

Assemble it all together and add an anchoring french cleat to affix to the wall. 

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Step Ten

Build your holders anyway you want

I have built pistol, rifle and whiskey holders. Be sure to add suede leather to the back so it won't scratch the finish.  If you want octagons, the angle is 22.5 degree.

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don't forget to finish the back, 

Alissa Rose

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Coming Soon "How They're Made" Youtube Videos 

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