This project was built and designed by Mike from Oregon Makers. Using salvaged wood and hand-finished details, he created a rustic sign that captures the feel of the Old West—perfect for adding character to any home, shop, or outdoor setting.
With barnwood, stencils, and simple paint techniques, Mike combines creative design with approachable woodworking to deliver a standout decor piece. The final result is rich in texture, nostalgic in style, and uniquely handmade.
Watch the full video and subscribe to Mike’s channel:
Why Reclaimed Wood Works So Well
Mike begins the project with a stack of reclaimed barnwood. Though dusty and weathered, each board holds years of texture and history that newer wood simply can’t replicate.
Rather than sanding away the character, he gently cleans the wood with a wire brush. This removes dirt and debris without stripping the patina, letting the natural weathering remain front and center.
Cleaning and Preparing the Boards
Once the barnwood is cleaned up, each board is trimmed to remove shiplap edges and inconsistencies. This step helps create a uniform surface when the sign is assembled but still allows each piece to retain its aged look.
The individual boards vary slightly in thickness and width, but Mike embraces those imperfections. When combined, they create an authentic, aged background that gives the sign its charm.
Gluing to the Backer Panel
To turn the loose boards into a single panel, Mike glues them down to a plywood backer. This creates a sturdy base that will hold everything together and keep the surface flat for painting.
Clamps and cauls are used to apply even pressure while the glue dries. This helps minimize warping and ensures a smooth face for the stencil and paint work to follow.
Adding a Rustic Edge Frame
Next, Mike cuts tongue and groove cedar to create an edge frame. The tongue and groove portions are trimmed off, but the beveled profile is left intact to keep that western-style look.
Rather than a precise, glossy finish, he goes for a worn, dry-brushed effect with chalk paint. The paint is applied loosely, allowing areas of the cedar to show through. This adds visual texture and keeps the edges from looking too polished or new.
Designing the Stencil
To bring the design to life, Mike uses a Cricut machine to cut a custom stencil. The design—Tumbleweed Flats—is laid out in design software, then cut from vinyl material that can be positioned directly on the wood.
One of the challenges with barnwood is that the surface isn’t smooth, so some parts of the stencil don’t stick well. To work around this, he tapes down any loose edges to keep the layout clean and aligned.
Painting for a Weathered Look
Using a stencil brush, Mike dabs paint into the design with a tapping motion instead of brushing. This technique prevents bleeding under the stencil and adds a textured, aged appearance.
Multiple tones are layered in—lighter and darker shades—to mimic the kind of fading you’d see from years of sun and rain. He uses acrylic paint and thins it with water when necessary to get subtle transitions and natural-looking blends.
Detail work is added with a smaller brush to highlight key parts of the design. The horse, in particular, receives careful attention with added shading and highlights to give it depth and movement.
Mounting and Final Assembly
With the painting complete, Mike prepares a French cleat for mounting. This hanging method makes it easy to install the sign on a wall while keeping it flush and stable.
The cleat is glued and screwed into the back of the sign for added strength. Corners of the sign are also reinforced using glue and brad nails, making sure everything holds up over time.
This attention to structure ensures the sign isn’t just decorative—it’s also built to last, whether it’s hung indoors or outside under a covered space.
A Great Blend of Creativity and Woodworking
Mike’s vintage western sign shows how a few thoughtful techniques can bring an old piece of wood back to life. From salvaging the material to designing and painting the graphic, every step adds to the unique feel of the final piece.
The project is approachable for woodworkers and hobbyists alike, and it’s a great way to explore creative sign-making without requiring advanced tools or complex joinery.
Watch the full video and subscribe to Mike’s channel: