Rustic Home Decor Wooden Sign Project

Finished

 

Here is a fun little project I just had to try! In the shop, I am being run out by lots of scrap lumber and a large accumulation of pallet wood. This rustic home decor wooden sign project seems to be the perfect way to put all leftover materials to use. Here is how I created it:

Tools Used:

  • Table saw and miter saw in 
  • Cordless drill
  • Pocket Hole Jig 
  • Hand Sander
  • Jointer/Planer
  • Silhouette Cameo Cutting Machine
  • Band Clamp
  • Hammer
  • Nail Gun

Materials:

  • (4) Boards measuring 1.5 inches in diameter and 13 inches in length.
  • (5) Plank boards measuring 3/4 inch thick and 16 inches in length. 
  • Any stain and/or paint you may have on hand.
  • Stencil material. I used left over vinyl.

Sign Cutting File:

 I got this file for my Silhouette Cameo 3 machine over at:

Surely My God File @Sofontsy website (not affiliated)

Another place to find creative fonts to use: CreativeMarket.com (affiliate link)

 

Step 1:

After cutting all the boards to size, I sanded down all the rough edges and marks to a semi-smooth finish. I didn't get too crazy in this process as I wanted to have a rustic look and feel when the sign was finished. 

Wood Sanding

Step 2:

I wanted to layout the board of the frame first to get a good feel of how the frame will look. I put the two 13 inch boards inside with the pocket holes lining up to the other boards. This worked out pretty good and made it easy to place my clamp around the frame. 

Rough Layout

Step 3:

Attaching the band clamp to the frame. This can be tricky but with a little patience and time, it will all be worth it. 

Band Clamp Frame

Step 4: 

Screwing in the screws using the pocket holes I made on the Kreg Pocket Hole Jig. These pocket holes were only created on 2 of the 4 boards. 

 

Kreg Pocket Hole Screws

Screws using the drill

Step 5:

Removing the frame from the band clamps and preparing the surface for the plank boards.

Removing the frame

Step 6:

Attaching the 3/4 inch plank boards to the top of the frame using glue and a brad nailer. 

Gluing the planks

Nailing the boards

Step 7:

I wanted to flush up the plank boards around the frame. Instead of measuring all the plank board exactly. I cheated and eyeballed them on the frame then cut them down to size on the table saw. 

Cutting Edge of plank boards

Cutting edge

Step 8:

Jointing the edges that I just cut using the table saw. This gets those plank boards down to being flush. Making for a more finished looking product. 

Jointer the edge of the boards

Step 9:

I had plenty of leftover stain from various projects. Truth be told, I am not sure if this stain is any good but it seems to apply just fine. 

Apply the wood stain

Step 10:

While I stained I also had the file cutting using my Silhouette Cameo 3 personal cutting machine. This is some leftover vinyl I had laying around and I was excited to find some use for it. 

Silhouette Cameo 3 cutting machine 

Step 11:

Once the vinyl material was finished cutting out. I decide to apply the stencil to the stain wooden sign. I used vinyl graphics transfer tape and some 3M painters masking tape to hold it stencil in place. Also, it was very important to work out any air bubbles in order to prevent paint bleeding under the cut-out letters in the vinyl. 

Removing air bubbles in the vinyl

Step 12: 

Another use for leftover paint, I decided to apply it to the cutout letter of the vinyl stencil. Making sure to be careful not to push excess paint under areas where the stencil may have lifted up and creating paint bleed. 

Painted stencil.

Final Project:

This was a fun and very easy project using leftover materials. The skills and tools required to make this project are very basic. You could use hand tools and other more materials to complete this project. I used what was easily accessible to me and found this will make for a great gift in the future. 

Finished Wooden Sign

Video of the project.

 

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