Take a old pallet that has some aged to it and make a USA shaped wall art.
Add a Teacher Note to share how you incorporated it into your lesson.
Step 1: What You Will Need:
1 aged pallet or pallet boards
Sawzall with metal cutting blade
Jigsaw with scrollsaw blade
Hammer and punch
Titebond II Wood glue
Elmers Craft Bond Spray Adhesive
Paper and printer
2 D-Ring hangers
3/8" Long screws
Step 2: Disassemble Pallet
Using a Sawzall with metal cutting blade. Cut the nails to release the pallet boards
Step 3: Remove Nails
Take a punch or old nail, and hammer all the left over nails out of your boards.
Step 4: Edging Boards
Rip the edges of your pallet boards, so they have a straight edge for gluing.
Note if you have a edge jointer use it instead of tablesaw
Step 5: Making Pattern
Find a pattern on the Internet and print it out to the size of your choice. I had already printed this one out with the flag, for intentions of making one like it, but didn't ( maybe later).
I use some Elmer craft bond adhesive, to attach my pattern to a piece of 3/16" hardboard ( this is for making others)
If you are just making the one, attach the paper pattern to your wood.
To see how I make my patterns with Inkscape, see my Mustang Pony cutout I madehere
Step 6: Arrange Boards for Gluing
Layout your boards onto your pattern. Place the real bad pieces or knots where they will be cut out.
Step 7: Clamp Your Boards
Clamp your boards and let them set overnight.
Step 8: Cleanup
After taking the clamps off, clean up any glue with a scraper or chisel.
Note glue your boards up, with the face side up and wipe off any excess before it dries, it will save you a lot of time. I got in a hurry and forgot.
Step 9: Trace Pattern and Saw
Now trace your pattern onto your pallet stock and cut with a jigsaw. I am using a scroll saw blade for the cutting.
Note take your time with the jigsaw, let the blade do the cutting. Do not force the blade, in some areas you will have to make relief cuts.
Step 10: Sand
Sand the edges of your wood with some sandpaper, I am using a sponge block. All we want to do is remove some of the rough edges.
Step 11: Attach Hardware
Now we are ready to attach the hardware. See the pictures for instructions
I am using D-Ring hangers and some 3/8" long screws.
Step 12: Enjoy
Now hang up your finished piece and enjoy your hard work.
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Note you can spray some sorta clear finish on it, but you don't have too. I like the rough character.