The Build Process for Our Rustic Wooden American Flag

Getting Started

The first step in building a rustic wooden American flag is to hand select the wood with particular attention to finding the ones with the most desirable grain pattern.  Next is cutting the 13 stripes to the correct length and sand each one.

The Burn Process

The next step is the burn process to bring out the grain which gives the flag the beautiful rustic look. I individually torch each one, which while more time consuming, it allows me better control to get the look I desire. I make sure to burn all four sides and then select the side with the best look.

Tinting the Wood

Using clear base stain tinted to the color I am using for the particular flag build, 7 of the 13 stripes are tinted. Allowing for adequate time to dry, the next step starts the assembly phase.

Assembling the American Flag

Using a biscuit joiner, slots are cut into each stripe, 5 for the longer ones, 3 for the smaller ones. The assembly process is actually done in 4 steps. Step 1 is to assemble the 7 smaller stripes. Each stripe is glued and the biscuit is inserted into the slot. Once all 7 are complete, the section is clamped together for about an hour. Step 2 is to assemble the 6 longer stripes. Same method is followed and once complete, these are clamped together as well.

The Union is carved out by using my Axiom CNC machine. The first step is to cut the Union to the correct size, then stain it. Once dry, the design is carved out. Step 3 is to cut slots into the Union and attach the smaller stripes using the biscuits. This section is now clamped together and allowed to dry for about an hour.

Step 4 of the assembly process is to join the longer stripes to the top half. These 2 sections are connected, glued, and clamped. Once dry, the finish is applied.

The Finish

The finish step is what makes the colors pop and brings the entire rustic American wooden flag to life. I take no shortcuts here as I believe this is a critical step. No spray on finish is used. I apply two coats of General Finishes High Performance Topcoat. Winner of the Woodworking’s Best Overall Choice Award, I love this product and the final result it produces. I sand after the first coat to give the 2nd coat the desired look.

I believe once you receive your rustic flag, you should not have to look for ways to hang it. I apply hangers and wire so that all you have to do it pick a spot on your wall, secure the proper size hanger to the wall, and hang your new flag up. Now you can proudly display your love for those who have sacrificed, and who those who continue to protect us and allow us to live in the greatest country in the world.

The Process