How They're Made
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.
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.
Slice in French Cleats
Plan your cuts to incorporate the 45 degree angle for French Cleats.
Assemble the bottom layer under vacuum
Use epoxy under vacuum to ensure it will be perfectly flat.
Lacquer spray 20-30 layers
Lacquer spray many coats and level sanding in between to achieve a perfect flat surface.
Sand and polish to an extreme level
Sand to 3k grit then compound and polish from coarse, fine to ultra fine.
Assemble the layers
Very carefully, assemble the layers with epoxy and screws. Remember, any scratches will be almost impossible to remove once assembled.
Select the wood and build the frame
I prefer floating frames but it's dealers choice.
Assemble it all together and add an anchoring french cleat to affix to the wall.
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.
don't forget to finish the back,
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