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Well was talking to an old friend from the Chief's Association and he was telling me the guy that was making their shadowbox's passed away not long ago and their supply of shadowbox was getting low. I told he I can probably make a few of these, of course I didn't let him know I have never done one of these in my life...so, I think I can pretty much handle the wood working part of this, just copy the one I have, but the Plexiglas part I am not sure of, I know this a woodworking forum, but I am sure someone here has made one of these. What I need to know, what thickness of plexi to use and how do you cut this stuff.

I plan on making a few standard boxes just to get him something quick. Standard meaning normal 24"x16" with a divider for the flag 3 inch deep. But I also have in mind making a few tricked out boxes like a wheel house box (saw one on ebay that was interesting) which will require cutting a 16" or 18" diameter circle out of plexiglas. Any input will be appreciated.
 

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I make smaller square and rectangular ones, using lexan, which can be cut on the table saw. Cut it and install it with the paper backing on both sides. Install and glue up, sand then finish. After the finish is dry, use an exacto knife along the edge of the lexan to cut the paper, and peel off. Keeps from getting finish on the lexan. This one still has the backing on the inside of the lexan:
 

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I've made a dozen or so and used Lexan in the flag cases and glass in the brag boxes. Main reason is, I can't cut a glass triangle too well!





Can't find my pics of the triangle flag cases, but these 2 pics may give you some ideas...And good luck, have fun.
 
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