Issue 1: The Tattered Soldier Flag
Target: Rough and Ready Flags | Owned and Operated by Mike Bell
Mike runs Rough and Ready Flags along with his wife and has been serving in the Army for 16 years - 15 of them in the infantry and now as a recruiter. He builds flags to help support his family when it comes to his sons medical costs outside of what the Army covers. Wheelchair ramps, tools to help him get around, furniture that makes it easier for him, Etc. His wife is his right hand woman who is ALWAYS out in the garage helping him complete orders and run the website behind the scenes. From Mike, “Thanks to Patriot Nation I’ve been able to greatly increase my sales through the files they all make. Special thanks to Taylor, Mike, Andrew, and Nick.”
“I love the infantry because they are the underdogs. They are the mud-rain-frost-and-wind boys. They have no comforts, and they even learn to live without the necessities. And in the end they are the guys that wars can’t be won without.”
Mission:
The most common question asked, “how did you make that.” We intend to start putting some of these questions to rest with this new blog series, “The Patriot Nation Gazette.” Today we are highlighting the most iconic and downloaded file from our website to date, the Tattered Soldier Flag. Mike Bell was one of the first to make a stunning product from the file and has graciously agreed to contribute to this blog! Our hope is this will serve as a great resource for other makers to see different styles, machines, programs, feed rates, bits, and materials that combine to make a great physical product! Each issue of the gazette will feature a specific file and highlight a maker and their process. We hope you enjoy this topic!
Operations:
Programs used: Carbide create and cut it through carbide motion.
Material & Size: Pine 19”x10”
Other Materials: Rust-Oleum Oramask
Bits: 90 degree V bit, 1/16” Endmill
Mike uses premium pine with his one piece flags. A common thing we get emailed about is stars being smaller and larger during the same cut. This can be especially apparent on larger pieces of wood. The smallest difference in height on the surface of your board can can cause large differences in how deep or shallow your bit will cut, leading to variations in star size. Ensure your board is as flat as possible - a planer helps followed by smooth even sanding. When your sure the board is flat Rust-Oleum paint can be applied followed by Oramask once the black paint has dried.
Now that it’s time to start cutting lets go over Mike’s toolpaths. With Carbide Create he set up 5 toolpaths: 1) the stars 2) the stripe outlines 3) stripe pockets 4) the “rip” space 5) the soldier. Other programs vary in how the toolpaths can be set up or handled and largely come down to personal preference, depth, material density, and machine performance. For the purposes of this article we will outline how Mike sets up his toolpaths using carbide create and carbide motion. Our hope is to grow the group’s knowledge and help each other learn, so please post any tips or toolpath info from other programs below in the comment section!
The Stars: 90 Degree V Bit
Depth Per Pass: 0.050 in
Feedrate: 45 in
Plungerate: 12 in
RPM: 18000
The Stripes (outline): 90 Degree V Bit
Depth Per Pass: 0.030 in
Feedrate: 45 in
Plungerate: 12 in
RPM: 18000
The Stripes (pocket): 1/16” Endmill
Stepover: 0.031 in
Depth Per Pass: 0.030 in
Feedrate: 45 in
Plungerate: 15 in
RPM: 18000
Start Depth: 0.0 in
Max Depth: 0.030 in
The “Rip” (pocket): 90 Degree V Bit
Stepover: 0.016
Depth Per Pass: 0.100 in
Feedrate: 9 in
Plungerate: 7 in
RPM: 10000
Start Depth: 0.0 in
Max Depth: 0.050 in
The Soldier: 90 Degree V Bit
Stepover: 0.016
Depth Per Pass: 0.100 in
Feedrate: 9 in
Plungerate: 7 in
RPM: 10000
Start Depth: 0.0 in
Max Depth: 0.050 in
Once carving is complete the white paint was applied followed with a light burn and infantry blue (or army green) paint for the line. The final step is a sealer to ensure it is protected! The finished product is a stunner with the original flag Mike made hanging on his wall in his home!
Mike Bell
We hope you enjoyed his work! Learn more about Rough and Ready Flags on their website: https://www.roughandreadyflags.com/
Write a comment, ask a questions, or provide other tips and ticks in the comment section below!