DIY Wood American Flag for Your Heros

by Kelly-n-Tony
15 Materials
4 Days

We have a teen in our neighborhood that wants to be a policeman when he's an adult. To encourage him to follow his dream and be the best person he can be Tony made him a wooden wall flag.

This one has the blue line and removable hangers to hang to his airsoft guns.

This could be made a simple flag with or without a blue line (or whichever color line you want) to mount on the wall or as we did with wood hangers to display something.

You can make your flag the size you want using this handy FLAG CALCULATOR that adjusts the proportions of your project but my directions will be mentioning the size we made this one.

Flag stripes...

1) Cut 5 pieces of 1 X 2 to 36 inches. Rip 2 of these in half with table saw to ¾ X ¾ pieces.

2) Cut 5 pieces of 1 X 2 to 21 9/16 inches. Rip 2 of these in half with table saw to ¾ X ¾ pieces.

3) Full size stripes and half size stripes are arranged in an “L” shape.

4) Clamp 1 X 2 stripes to the drilled standoffs using clamps.

5) Drill 3/8 hole in stripe to depth required for ¼-20 threaded insert for your screws.

7) Layout stripes on your plywood base (shown further below) to drill mounting holes. I used 4 for long stripes and 2 for the short.

8) Set the inserts into the 5 stripes: 4 holes for the long and 2 holes for the short.

"shou sugi ban"

9) Use a propane torch to burn the wood grain in the stripes. We love the look and it's rather fun to do!

10) On one stripe, after burning, I used liquid bluewater color dye diluted with water to create the “Police” blue stripe.

The flag base---

11) Our flag was to be a maximum 3' wide so using the calculator linked earlier we cut a 1/2" thick plywood that was 2' x4' in size down to 36" x 19-1/2" which made it proportionally correct.

12) I have a Cricut machine and was able to make my stars also proportionally correct thanks to this FREE flag stars svg stencil HERE for personal use.

13) Holes were pre drilled to hold the wood strips (the flag stripes) that will be attached through the back.

Stain the flag base plywood & remove the vinyl stars....

14) We thinned out some black paint we had on hand and used it like stain and wiped it off leaving a nice wood grain look still. If you dab carefully around the sticky backed vinyl stars it won't bleed underneath.

15) Once it's dry you're ready to remove the vinyl stars to expose the light wood color. Tweezers work really well to remove the vinyl stars.

16) Assemble the stripes to the front of the flag base using 1 ¾ long ¼-20 flat head screws. Screw them in from the backside so the front looks good.

17) Knowing this was going to hold a lot of weight we used what is called a French cleat system for the wall mount.

Here you see it's coming together but we're not done just yet! It needs a simple frame around it!

The frame--

18) Burn the 1 X 3’s with the propane as before. Then stain them a darker color and attach them with brad nails as a simple frame around the flag. Frames are easy!


19) Using the 1x4 cut the hangers using a scroll saw and the pattern supplied below.

20) Burn the wood to match the stripes and simply hang them on your stripes to hold what you wish to display.

And here it is ready to be hung. We love the wood look that shou sugi ban gives and it's really popular in all kinds of wood projects.

This is a hanger pattern for the project
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