Faux Wood Panels!

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About: My wife and I have a home haunt called Terror On 20Th....I love to build props...everything from a casket to pneumatic monsters! I am also a presenter, speaker and course teacher at Halloween conventions.

So a friend had a garage door in her business that everyone would see and needed to dress it up. It had to be super light weight so the door would still open. This is an easy fun project and can be used in many applications.

Supplies:

You will need 4x8 sheets of 1/2" pink insulation foam,a few sharpie markers, a tape measure, a straight edge, an adjustable wood burning tool or soldering gun. A wire brush with wood handle, razor cutting knife, hand held torch, paint supplies (roller and brush) and a few different color paints. (flat latex wall paint) Loctite Power Grab instant grab glue. SAFTEY...I would recommend some good gloves, eye protection and good respirator type mask. When carving the foam be sure to be outdoors or in a very well ventilated area.

Step 1: Let's Get Started!

1. Cut the panels to size (all depends on where you will use them) I used the straight edge (I used a drywall T) to draw out my cut lines then used a razor knife to cut out the panels.

2. Using the straight edge and a sharpie I start to lay out the board pattern. I kept it sort of random with some boards being wider. The idea is that these are recycled barn boards, old and half dried out.

3. Now I start to draw out the wood pattern on each board, I start out with the knot and then draw a random pattern extending away from the knot and keeping the lines about a 1/2 inch from each other. Easy once you get the hang of it.

Step 2: Carving Out the Pattern.

1. Using my soldering gun on a medium setting with the pointed tip I was able to "glide" the tool through the pattern.....gotta keep moving or the tool will melt the foam deeper and wider. I would suggest using a scrap piece first to get the hang of how fast or slow you will need to go. I melt the tool tip in about half way. This looks a bit strange at this point I know.

Step 3: Time for Some Fine Detail!

Be sure to get a wood wire brush, I started out with a plastic one and when I heated up the wire it melted and the wire came out!

1. I set the torch on medium and heated up the wire brush. You should only need to heat it for 30 sec or so.

2.While the wire is hot start out at the end of each "board", angle the brush at about a 45 and slowly drag across letting the wires melt in. Be sure to "wiggle" the brush slowly now and then. Just keep repeating this step until you get the desired effect. This will also help "harden" the foam. The brush will also open up some of the carved lines and give it a much more natural aged look. Be sure to "sit" a bit longer on the ends of the boards as this will be where more aging would be.

Step 4: Time for Finish Paint!

1. I used a very dark brown flat latex interior wall paint for the base, almost black and a thick roller to apply. Be sure to get paint into all of the grooves so that NO pink is showing...this is a pain as I found out! Every time I think it was good another angle would show a bit of pink!

2.Once you are sure the base has fully covered all of the pink and the panels are DRY it's time for the finish coats.

3.This will be a dry-brush technique. You will not need much paint for this step. Using a color several shades lighter, dip just the end of the brush into the paint...using a scrap bit of foam or cardboard brush the pain on until it's just about all off the brush.

4. VERY lightly in the opposite direction of the "grain" brush across, do small sections at a time. This should go fast but be careful not to add to much paint. I also add a few other colors such as a bit of green in a few boards.

Step 5: Finish It!

After the dry brushing is done on all of the panels I set them in sunlight to "check" for light spots or where I may need another color. That's about it...you can use any color as a top dry brush coat. Next time we are doing a wall and will have different staggered colored boards, red and grey.

Step 6: Install!

I used power grip to glue the panels to the door...just a few dabs was plenty and there is no "wait" time once you press the panels on. Most important the power grab will not eat into the foam.This is very light weight and easy to work with! Have fun!!

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    16 Discussions

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    dainsworth

    7 hours ago

    Looks great! A beat-up wire brush dragged across the surface of the foam makes for an excellent wood grain effect. Jam the tip of the brush into the foam and twist to create knots.

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    gunnerjake81

    10 days ago

    I was going to comment about the dangers of adding weight to garage doors and was instantly impressed with your creativity. Great work!

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    altomic

    10 days ago

    nice instructable. i'm not going to faux-get it

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    sheba92766

    12 days ago

    That was freakin' cool! This is one of my most favorite Instructables. This could be used in so many applications. Thank you for sharing.

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    Denzelian

    13 days ago

    Nicely done! Plus it will help insulate the room it's in, so it's practical as well as decorative.

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    PaulChau

    14 days ago on Introduction

    Wow, it looks like you really spent a lot of effort on this mate! It looks really great after you've coloured it in and worked out the grooves! The final look is really quite impressive and it's something you're going to be proud of having in your house now!

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    Eh Lie Us!

    18 days ago

    what kind of witchcraft is this?!? Freaking amazing work. I'd would have added a little 1/2 nest. Or an owl peeking out of tree cavity! :) Thanks for posting.

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    rch

    20 days ago

    Very nice! These turned out quite well.

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    XRay7

    20 days ago

    Me: "What an insanely great idea! How can anyone be so creative?"
    ...
    Me: "Oh. It's my already-favorite faux-brick-wall-garage man again. - Well, that explains everything!" :D

    Really cool! Hard to believe there's still pink foam underneath there somewhere. :D

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    JasonF205XRay7

    Reply 19 days ago

    Thank you very much! I mostly build Halloween stuff but this was fun!