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This plan walks you through how to make a rustic wood American flag.
| Item | Qty |
|---|---|
| Boards, 1x2x10 | 5 board |
| Board, 1x3x10 | 1 board |
| Wood glue | 1 each |
| Box 1" nails | 1 each |
| Box 1 1/4" Kreg screws (see tool list) | 1 each |
| 2 each |
| Hanging cord | 1 each |
| Cans of spray paint (red/white/blue) | 3 each |
| Painters tape or masking tape | 1 each |
| Polyurethane | 1 each |
Overall cost: $$. Lumber prices vary by region, species, and season, so we give a band rather than a figure we would only be pretending to know.
| Part | Qty | T × W × L |
|---|---|---|
| 36" pieces (1x2 wood) | 13 | 1" × 2" × 36" |
| 18” pieces (1x2 wood) | 2 | 1" × 2" × 18" |
| 36” pieces (1x3 wood, 45 degree angle) | 2 | 1" × 3" × 36" |
| 19.5” pieces (1x3 wood,45 angle) | 2 | 1" × 3" × 19 1/2" |
Buy 9 boards at 8 ft.
2 boards
7 boards
Assumes 8 ft stock, a 1/8" saw kerf, and buying each part at its own width. Change the board size or kerf on the full board plan →
Start by cutting your 1x2s down to 36" (13 pieces). Cut 2 18" pieces from the leftover wood.
Lay your 36” strips of wood on a flat table or wood clamps and organize them however you like. I like to keep the knots on the stripes that will be painted.
Glue your strips of wood together and clamp them down. Allow it to dry for at least an hour.
Take your 18” strips/brackets and glue one to each side of the flag. Make sure you don’t cover the pocket holes.
Add nails to the 18” brackets (1 nail in each strip, 13 total).
Turn the board back over and sand first with 80 grit and finish with 220 grit.
Tip: See Extras tab for a link to the star stencil.
Tape up all the white stripes and the Union (star area) Paint your stripes red and allow the paint to dry for 1-2 hours.
Remove the tape and add your star stencil back to the upper left corner. Tape around the sides and put cardboard over the rest of the board. Use the white spray paint and lightly spray the stars. Let dry for 20 minutes and add another slightly heavier coat.
Use your propane torch and burn all of the white stripes.
Put the 19.5” pieces on each side and the 36” pieces on the top and bottom. Secure them to the flag by using the pocket holes from the back with 1 1/4” screws.
Use the propane torch to burn the inside/outside of the frame.
Turn the board around and add your hanging cord. Cut the cord to desired size and secure it to the flag using 1/2” screws with washers.
Last step is to add 1-2 coats of polyurethane.
Enjoy your flag!
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