Wonder Woman Shadowbox
Initial Mockup: A very rough prototype about one-third the size using pallet wood and plywood — stars drawn by hand to test layout and proportions.
Cutting the Face: Two concentric walnut circles routered at 22” and 25” for a perfect 1½” face. Face panel built from three edge-glued walnut boards for minimal seams.
Precision Matters: Close-up of the measuring tape confirming a clean, even 1½” face. Every detail checked and rechecked.
Internal Layout Planning: Planning out the case depth with a divider and a folded flag for scale. The octagonal body saves on cost while allowing for a multi-layered build behind the face.
Joinery in Progress: Case pieces joined using dominoes for strength and precision. A rock-solid base for the layered design.
Creative Clamping: Octagon clamped using a strap system and a custom-cut triangle block for clean support during glue-up.
Three Layered Assembly: The full assembly before cutting - face on top, two layered panels beneath that will form the case body.
Circle Cutting: First circle fully cut, second one in progress — router still mounted at center pivot.
Face Recessed for Glass: Back side of the face routered to create a clean inset for UV-protective glass.
Smooth and Ready: Face sanded to a buttery finish, ready to be joined with the case layers.
Glue-Up in Action: 25” diameter, 1.75” thick body glued and clamped around the full circumference — strong and solid.
Star Layout: Maple stars laid out and measured for precise placement around the face.
Hidden Hardware with Magnets: Clever joinery - screws attach the face to the case if there's ever need for future glass replacement, while magnets attached to each star snap onto the screws to hide them.
Recessed Back Panel: Back routered for a plywood insert to support the insignia and folded flag from within.
Final Assembly: Stars and engraved Wonder Woman logo installed. Shadowbox laid on a towel to protect the finished product.
Internal Divider: A routed groove hides a divider between the flag and insignia compartments. Visible here for reference.
Depth View: Side angle shows the shadowbox’s solid 2.5” depth with finished walnut frame and maple trim.
Finished Piece: The final product - 25” diameter walnut frame, maple accents, UV-protective glass, and a legacy of service that will be captured in wood.
Legacy Preserved: The completed shadowbox, now filled with the client’s insignia and folded flag. A meaningful tribute, custom-built to honor a lifetime of service.