This project was built and designed by Drew Fisher from Fisher’s Shop. It’s a visually stunning American flag made from wood that appears to wave, adding movement and depth to a flat surface.
The build combines precise shaping, power carving, and finishing techniques to bring this effect to life. It’s a rewarding project that balances craftsmanship with creativity.
Watch the full video and subscribe to Drew’s channel:
Designing the Template
Drew begins by designing a reusable template that includes a series of gentle arcs. These arcs are arranged diagonally, creating the illusion of a flag waving in the wind.
The template is marked with evenly spaced reference points to help align the wave pattern across the individual stripes. Each board will follow this curve to ensure visual consistency from top to bottom.
Preparing the Materials
The full-scale template is printed at a 1:1 ratio and adhered to a thin board with spray adhesive. This makes it easier to trace the pattern onto each individual stripe.
Drew cuts the outline using a bandsaw and refines the edges on a spindle sander. This step ensures that the curves are smooth and repeatable for every stripe.
Five 2x4s are milled for the build, each yielding three individual stripes. After planing, there are 15 total strips, giving a few spares in case of errors.
Planing the boards ensures that all pieces are uniform in thickness, which is critical for both gluing and carving. The result is a consistent and flat flag panel.
Shaping the Wave
The wave pattern is transferred to each stripe using the template as a guide. The bandsaw is used to cut the curves, allowing for a little flexibility in the exact line.
This step doesn’t require extreme precision, which helps speed up the cutting. Each stripe is shaped individually, but they will align visually once assembled.
Gluing the Stripes Together
Drew uses Titebond III to glue up the full panel. Its long open time allows for adjustments during the clamping process.
Each stripe is aligned carefully to keep the wave flowing across the surface. Once everything is dry, the panel is removed from the clamps and ready for carving.
Power Carving with Arbortech
The surface carving is done using an Arbortech Turbo Plane, a power carving attachment that removes material quickly and cleanly. It’s ideal for smoothing the ridges between stripes and enhancing the wave effect.
The tool produces wood chips instead of dust, making cleanup easier and reducing airborne debris. Drew gradually blends the curves until the waving effect is smooth and natural.
Smoothing the Surface
After carving, a flap disc sander is used to level any remaining rough spots. The entire panel is then sanded by hand up to 220 grit for a clean and smooth finish.
This step prepares the surface for burning and staining, ensuring the detail work looks polished in the final piece.
Burning the Stripes
To darken the red stripes, Drew uses painter’s tape and high-temperature foil tape. The foil provides clean, crisp lines while reducing the chance of burn-through.
Applying tape around curved edges takes some time and patience. Once masked off, a torch is used to burn the exposed wood, enhancing the grain and adding dramatic contrast.
Keeping the flame moving ensures an even result and prevents scorching. Any rough patches can be lightly sanded before the finish is applied.
Creating the Union and Carving the Stars
The blue union is masked off and sprayed with a single coat of black paint. After drying, a star stencil is used to outline each star on the panel.
A rotary tool is then used to carve each star by hand. While the process is detailed, it adds a crisp, handmade look to the flag.
Applying the Finish
Drew finishes the flag with several coats of spar urethane. This glossy finish enhances the color contrast and brings out the texture of the grain.
Between coats, he sands lightly to smooth the surface and build up a durable layer of protection. The end result is both visually stunning and well-sealed for display.
Bonus Project Potential
With careful planning during the cutting phase, the leftover offcuts can be saved. These are ideal for making a second, smaller flag using the same techniques.
This gives you another chance to refine your process or create a gift-worthy piece without additional material costs.
Final Thoughts
This waving American flag project combines technical woodworking and artistic design. It’s a great way to develop your carving skills while creating something patriotic and unique.
Whether hung indoors or displayed in a workshop, this piece is guaranteed to stand out. It’s both a showpiece and a personal achievement for any woodworker.
Want to See the Full Build?
Get Drew’s plans here: https://fishersshoponline.com/plans/p/fishers-waving-american-flag