This project was designed by Biscuit Tree Woodworks, and it’s a fantastic way to showcase your woodworking skills while celebrating patriotism.
Materials and Tools
- 1″ x 10″ x 10′ common whitewood board
- Minwax Premium Water-Based Stain in Crimson and Marine Blue
- Construction adhesive
- Spray can lacquer (clear satin)
- Handheld Dremel tool
- Razor blades
- Clamps
- Miter saw
- Table saw
- Foam brush
- Rubber ink roller
- Aluminum French cleat for hanging
Step 1: Cut the Wood
Start by cutting the 1″ x 10″ x 10′ board into three pieces that are each 37 inches long using a miter saw. This will form the main body of your flag.
Step 2: Create the Stripes
Next, set the fence on your table saw to 1.5 inches and cut the stripes for the flag. You’ll need enough stripes to create the alternating red and white sections.
Step 3: Char the Wood
For a rustic look, use a torch to add a medium char to all the pieces you cut. Don’t worry about making everything perfectly even; a little variation will enhance the flag’s character.
Step 4: Layout the Flag
After charring, lay the pieces out on your workbench to find a pattern that you like. Look for knots or grain patterns and arrange the pieces to avoid clustering them together.
Step 5: Mark for the Union
Measure over 14.75 inches from one end and mark where the union will go. This will be where the stars are placed, so keep it clear of knots or busy grain patterns.
Step 6: Prepare for Staining
Take every other stripe and move them aside. These will be stained red. To prevent bleeding, place razor blades along the edges of the union area.
Step 7: Stain the Stripes
Use Minwax water-based stain in crimson for the red stripes. Apply it with a foam brush, ensuring the wood grain shows through. Repeat the process for the blue union area.
Step 8: Assemble the Flag
Once the stain has dried, reassemble the pieces and clamp them together. Apply a little glue to each stripe, just enough to hold everything without excessive squeeze-out.
Step 9: Add the Stars
Using a stencil for the stars, secure it in place and use a Dremel tool to carve out the shapes. Start with a small bit for the outlines, then switch to a larger bit to fill them in.
Step 10: Final Touches
After carving the stars, use a small torch to add a bit of color back to them. This helps them stand out against the stained wood.
Step 11: Mount the Emblem
If you want to add an emblem, roughen the back for better adhesion and use construction adhesive to secure it in place.
Step 12: Finish the Flag
Apply a clear satin lacquer finish to protect the flag. Allow it to dry before flipping to coat the other side. Once dry, it’s time to hang your beautiful creation!
Step 13: Hang Your Flag
Use an aluminum French cleat designed for heavy artwork to hang your flag securely on the wall.
With these steps, you can create a stunning wooden American flag that will be a proud addition to your home. Thank you for following along with this project by Biscuit Tree Woodworks!
Video