This is an expansion upon the fun flower fence instructable. http://www.instructables.com/id/How-to-make-a-Fun-Flower-Fence/
When I was out of town a few months ago, my wife surprised me by building a gate for our picket fence. She told me on the phone that she did this. She is actually a good woodworker, so I was expecting something pretty nice. Surprise! The gate was a pallet that was painted yellow and attached with hinges. It was big and heavy. But, it was a gate, which we needed for our dog (now 2 dogs). I have waited a respectful amount of time and now I am ready to fix the gate.
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Step 1: Materials and tools
Table saw or radial saw (You can skip this if you are using pallet wood and tying it to another fence)
Band saw, Scroll saw or jig saw to cut flowers
Rotary tool or wood carving knife
Step 2: Cut Stems
Paint them green, unless you would like some other color stems.
Step 3: Cut Flowers
Trace a flower design on the wood.
If you are making a complete fence, it helps to cut out a template for the flower out of hardboard. You can paint the template and drill a small hole in it to decorate your shop space.
Cut out the flower. I cut into tight corners with my band saw to avoid binding the saw blades on the flowers curves (see pics).
After you cut out the flower shape, round over the front edge of the flower with your router.
The next step is to carve out the flower details with the dremel rotary tool. The flower here has very basic details, you can carve them more intricately if you want.
Step 4: Paint flowers
Step 6: Attatch flowers to stems
Find exterior screws that are just a bit shorter than the thickness of your flower and stem stacked together.
Pre-drill the holes for the screws. Screw the flower to the stem through the back of the stem. Use two screws in the flowers for strength and to avoid spinning the flowers.
Do not attach the leaves yet.
Step 7: Make a Z frame
Make a Z shape for your gate. I used 2X3” boards, though typically gates are made with 1X4” boards, I used what I had and you can too.
My gate is 32” across I spaced the boards so they would look okay with the existing fence. After placing the two cross pieces where I wanted them I laid the diagonal board in position. Then I marked the position of the cross pieces so I could make the cuts. After, making the cuts, I redid them a second time bit neater, oops.
Then I placed the diagonal board in position and pre-drilled holes for the screws.
This is all that you need for a normal gate. But, here I don’t have access to gate hinges, so I am using 3 inch hinges. I decided to add a support piece for the hingesas shown in the photos.
Step 8: Place the pickets
I placed the two end pickets first. Then I just placed the other pickets on the frame until I was happy with the look.
I placed the leaves on the gate. Then I lifted up each stem, while holding on to the leaves and pre-drilled and screwed the leaves on to the stem from the rear.
The pickets are then predrilled and screwed down to the frame.
Some of the flowers could only be screwed in one place because of the frame and where the flowers were. To secure these flowers, I flipped over the gate and pre-drilled and screwed the flowers and/leaves to other flower stems from the back side of the gate.