I have seen large amount of people making different varieties of flags, and they are cool aren’t getting me personally incorrect, but I became hunting for one thing a little from the ordinary.
i desired my banner to really have the look it was waving when you look at the wind. Because of this task, we used the ArborTech turbo air plane attachment that continues an angle grinder, but it is maybe perhaps maybe not essential if you do not occur to obtain one. In reality, there is a number of different ways that you might use to accomplish an identical impact therefore simply because there’s no necessity the same tools that i would be utilizing, never compose this project off as something you cannot do. I highly recommend watching the embedded movie to get good notion of just what each step of the process requires. There is just so much I’m able to convey through still images and a video with voice over can paint a better photo often. Without further ado, let us get going!
Action : Materials & Tools
For materials, it really is pretty straighforward.
- You will need a pc and printer in order to print the templates off
- Clear packing tape
- An item of slim stock for the flag stripe template (3’4 1/4″ long, 2″ high, approx 1/4″ dense)
- Craft Spray Adhesive
- Five straight 8′ long 2x4s
- Wood glue
- Painter’s tape
- High-temp HVAC foil tape
- Ebony spray paint
- Masking product (for example. Newspaper, butcher paper, synthetic fall fabric etc.)
- Some form of lumber finish (in other terms. SPAR Urethane, Polyurethane, Lacquer, etc.)
- D-rings for hanging finished item
- Scissors, tape, and razor blades (or exacto blade) to cut out and patch together the templates
- Tape measure
- Bandsaw (Steps with bandsaw might be finished with a jigsaw if not a coping that is hand-held)
- Spindle sander (procedures with spindle sander could possibly be carried out by hand sanding)
- Planer (procedures with planer might be through with tablesaw)
- Jointer (procedures with jointer could possibly be through with tablesaw)
- Miter saw (procedures with miter saw might be through with handsaw)
- Pipe/Bar clamps
- Angle grinder with timber attachment that is carvingi.e. ArborTech’s Turboplane)
- Flap disk sanding attachment
- Sand paper
- Propane torch
- Rotary device with timber carving bit (measures with rotary device could possibly be completed with hand carving tools)
- Brush for using finish
Action : Design & Templates
To generate the waving appearance, I experienced the theory to make use of a curved template with 13 offsets (one for every stripe into the flag). I quickly could locate the curvy line onto each stripe board but begin each one of these at yet another offset mark in the template. As soon as most of the panels are cut away and set together, it makes a diagonal revolution pattern.
down load the PDF template above and print it away on your desktop
Cut it out, patch together the parts, and secure it with tape
For a section that is later you will need to locate the union movie movie stars on the banner. There are a selection of choices you should do this however the fastest and simplest, I think, would be to just download the template below and cut fully out all the movie movie stars by having a knife that is exacto energy knife.
down load the PDF template above and print it out on your desktop
Cut it away, patch together the parts, and secure it with tape
place a layer of packing tape over the front and straight back of this template to thicken it
cut right out all of the movie movie stars really correctly with an exacto knife or Utility knife
Action : Building the Curvy Stripe Template
after the template is cut fully out, prepare a piece that is thin of to adhere it onto. This piece should always be exactly 3’4 1/4″ long and around 2″ high. If you do not have a bit of stock this size, you can get away with only making use of cardboard.
Then, use some craft adhesive to affix the template down onto the stock. Should your stock was not cut to size, you are able to do it only at that right time given that the template demonstrably identifies how long it must be.
with all the template glued onto the board, now you can cut it away over at the bandsaw. You can use a jigsaw or even a hand-held coping saw for this step if you don’t have a bandsaw.
After cutting out of the template, it is possible to smooth the curves out by making use of a spindle sander or by hand sanding.
The last action is to move the offset markings from the template on the timber. I did so this by scoring each mark with a computer program blade after which darkening each cut mark by having a pencil after the paper template had been eliminated.
to get rid of the paper template effortlessly, work with a heat gun or locks dryer to loosen the adhesive and just peel from the paper. In all honesty, it is not also all of that crucial that the paper be eliminated.
Action : Dimensioning the Stripes
action 13 is always to cut 13 stripes. 🙂 get started by cutting the stripes to 2′ 7.5″ each. That is 1/4″ more than their last size is supposed to be but will permit some slop through the gluing stage. And also this lets you effortlessly get 3 stripes for every single 8′ 2×4 you cut. Whenever cutting up 5 2x4s you are going to end up getting an overall total of 15 stripes so that you’ll have 2 extras in case one of many other people has some flaws that you don’t like.
The next thing is to obtain each one of the stripes for their last depth of just one 1/4″. I did so this utilizing my planer, however you could just like effortlessly attempt on the table saw. In one pass, just raise it slightly over half the height of the board and make two passes, flipping it end for end between cuts if you can’t raise the blade high enough to do it.
within the video clip, i personally use my jointer to simply just just take from the rounded sides of this 2x4s then reference that square side against my tablesaw fence and tear each stripe to it really is last height of 2 1/2″. You could just use your tablesaw and make 2 cuts per stripe (1 to trim off the rounded edges on one side, 1 to trim it to final height while referencing the square edge against your fence) if you don’t have a jointer,.
Action : Marking and Cutting the Stripes
With your stripe template, line up the very first side against the side of one of the stripe panels. Ensure that the bottoms are flush then locate the line for the entire duration of the board. For the next stripe, fall into line the template once once once again but reference the first offset alternatively of the advantage. Try this for each stripe board you have actually whilst each and every time referencing the second offset mark regarding the template. Make sure to host each board as your mark them having to pay consideration to also host the offcuts while they will be accustomed produce a 2nd flag.
Once each stripe board has been marked along with its curvy line, check out cut every one out over during the bandsaw. If you do not have bandsaw, this can be done by having a jigsaw. Then it’s possible (however exhausting to even imagine) to do it by hand with a coping saw if you don’t have a jigsaw. Make your best effort to keep in the line whenever cutting, but it isn’t the conclusion associated with globe in the event that you veer down a little because this task has plenty of forgiveness (all of the flaws will likely to be ground down through the subsequent actions).
Action : The Glue Up
with the stripes cut fully out, put them in your pipe/bar clamps within the order that is proper plan the glue up. We utilized just standard Titebond timber glue but my banner is hanging regarding the wall surface in my own workplace. If yours will soon be outside, make sure to make use of water-resistant or wood that is waterproof (in other terms. Titebond 2 and 3).
Glue up each stripe and clamp to dry having to pay really unique focus on maintaining things square. It’s also extremely tough to make use of caulling boards due to the wavy the surface of the banner therefore be sure to make your best effort to make things flush on the bottom.
When it is dry, eliminate through the clamps and clean down any glue squeeze away regarding the base of this banner. You’ll overlook the edges and the surface of the banner since that may all get ground down into the step that is next. If you have got a card scraper, that may work very well for getting rid of the items of dried glue. Otherwise, you should use a grit that is heavy to smooth things down.
Action : Shaping and Sanding the Flag
To contour the banner, I utilized the TurboPlane from ArborTech. It is a little steel disk with some cutting notches that attaches onto your angle grinder. This created for extremely fast shaping and carving! Nevertheless, if you do not have the TurboPlane, there are numerous other lumber carving attachments as possible get for the angle grinder that could have just like similar impacts. Find the one that works in your favor then grind from the sides of all the waves to smooth things down.