Toy Pattern: Flag

Tools

• Band Saw or Scroll saw
• Sanders – Disc, Belt and Spindle
• Router with 1/8″ round over bit
• Drill Press
• Sand paper or emery boards

Material

• 3/8″ lumber
• 1/8″ dowel

Instructions

1. Make pattern from print of Flag and base by gluing to a piece of cardboard. Cut pattern to shape.
2. Draw shape on wood surface and mark axle centers.
3. Saw flag and base from 3/8″ lumber (sand sides smooth). Fill any voids, cracks or knot holes with filler. Stack 2 or 3 pieces together with double faced carpet tape. Attach pattern on top with tape and saw out flags at the same time. Similar process for the bases Stacking will aid in smoothing the cut edges.
4. Separate stacked pieces and sand surfaces with a belt sander. Round over all edges with 1/8″ bit using router table.
5. Drill 1/8″ holes in flag and base for flag pole.
6. Sand cut surfaces with a Disc, Belt or Spindle sander to smooth.
7. Sand edges to remove roughness.
8. Cut 1/8″ dowel to 3″ length .
9. Assemble flag pole to flag and base using white or yellow glue.
10. Rub your hands over the entire vehicle to make sure there are not sharp edges or points. Remove with sandpaper if any are found.

Download pattern here.