One of the most inspired and patriotic projects that a woodworker can build is a flag case. Building a flag display case primarily involves standard cabinetmaking tools and skills, but how on earth do you cut those sharp miters on the base? The base corners of a traditional flag case feature 45-degree angles, so each piece must be cut to a 22.5-degree angle, which looks like a knife’s edge compared to a traditional 45-degree angle cut used for most miter joints. Table saws and miter saws both suffer from the same problem: the blade can’t be set to the incredibly steep angle required for this cut.
Learning how to make these cuts requires an understanding of how to cut angles on a table saw. The key is to push past the boundaries of the table saw by utilizing a jig that allows you to cut at the appropriate angle.
To extend the saw’s capabilities and enable it to make a 22.5-degree angle cut, you’ll want to use a tenon cutting jig to hold the work piece vertically as you make the cut. With the work piece oriented vertically, you are able to set the table saw blade at 22.5-degrees and make the cut.
Accurate angle calibration is a must. It is critical that you set the table saw blade to exactly a 22.5-degree angle so that your flag case will have nice tight miters. This is best done by using a digital angle gauge.