First cut the balsa to the desired size and lay it aside. Using the 6
inch proportion as a guideline for these directions, cut a 2 inch piece
of tubing and ream the ugly ends with your pocket knife. Clean up the
outside with a small file if you want to. Now, cut an inch length of
the "tight fitting" wire and file or stone the ends square and smooth.
Slide the 1 inch wire into the 2 inch tube until the ends are flush and
crimp the 2 together with the diagonal pliers. Make several crimps in
each if you think you need to but be careful not to bend the tube. Make
one of these for each flag.Draw a line down the center of the flag
and use the hobby knife to cut, scrape and gouge a slot for the tube
assembly you just made so that 1 inch of the tube is into the flag and 1
inch out (like the picture). If you think you need to drill the flag
please do. Epoxy the tube into the balsa and get it straight. When the
epoxy sets, paint the flags.
Cut the wooden dowel rods into lengths of about 4 inches and use your
ingenuity to make a hole in the one end of each about the same size as
the "loose fitting" wire - make it a half inch deep. Cut the wire into
2 inch lengths and epoxy it straight into the holes. Be sure you leave
enough wire sticking out to hit the stop in the tube with a little left
over. You can straighten it with your thumb if you make one crooked.
When the epoxy sets, file a sharp point on the end of the wire. If you
intend to use music stands or stands with similar tubing, use the
masking tape to wrap the dowel rod so that it will not fall into the
tube (make a stop). You can also wrap the end that sticks into the
stand a few times to take out the play where the dowel doesn't fit
tightly.