Dimensionalizing the octagon sides.

The importance of each piece being exactly the same size.

• In order for an octagon to work, each side must be the same size so when a 22.5 degree edge is cut, it will fit together perfectly. But first, you have to account for any miss-alignment of the flag to the wood. It won't be perfect but I can get close. It's hard to tell in the above picture but the flag is slightly sideways by 3/8 of an inch.

• This is a Tapering Jig which allows you to straighten up the flag.

• In the above picture, you can see that the stars align well up against the left cutline.

• Once the cutline is established, I cut the flag into strips to the desired height of the octagon cooler. The inside metal liner is 13 inches tall so for safety sake, I cut the outer flag height to 18 inches. This will account for attaching the top and bottom; as well as insulation.

• Now this needs to be cut into the octagon sections. It's important that each section is not only the exact same size, but a perfect 90 degree vertical cut. That's where the cross cut sled comes into play.

• Which brings us to 8 perfectly sized sides for our octagon cooler.

What did this cost?

Outside of having the correct tools, there are no material costs associated with this section. One thing to note is to deliver precision, having the right tools is mandatory! For example, I have 10 different table saw blades with the cost of each averaging $200+. The Incra cross cut sled is also not a cheap tool. It is also important to note the importance of properly tuning your jigs and tools. Any misalignment creates a world of problems further into the project. Slow careful planning and measuring is absolutely the fastest way to complete projects like these!

What is the next stage?

Cutting the 22.5 degree angle on each side of the octagon sides and then glueing them up. I still have not decided on how to attach the bottom and top of the cooler. I need to think about this more before I glue up the octagon. If anyone has any suggestions, please SHOUT OUT!

Have any questions? Ask away!

Mark Petrilla, Gorilla Bark Studio's

Paying tribute to those who keep us safe.