Step 1: Lumber
Step 2: Steel Frame
Step 3: Design
This will require some Photoshop wizardry, but basically convert the image into greyscale and adjust the levels until you reach (or come close to) a black and white image. The main thing is to create a stencil. From here, either use Illustrator ("live trace" command) or CorelDraw ("outline trace" command) to convert the image into a vector outline. Because of the level of detail, I used a CNC vinyl cutter, but this would still be doable with a large print out and x-acto knife if you had a simpler design (or a lot of patience).
I used old vinyl that no one wanted (might have been the color...) since I just needed it for masking. Use transfer paper to get the portrait and lettering onto the wood slats.
Step 4: Paint and Peel
In the end, this project was done in a day by using up scrap -- basically this is my version of cleaning! All free, too.
Don't have the tools? Come down to TechShop and I'll show you how to use them! Don't live near a TechShop? Then get with your friends and community to build your own workshop or hacker space!