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Picture of Pallet Wood American Flag (A.K.A. the Pyro Flag)

With a brand new (to me) tablesaw and Memorial Day right around the corner, this project was just calling my name. As always, I tried to make everything from scrap that would otherwise be heading toward a dumpster when possible. Enjoy!

DISCLAIMER: Sorry Brits, Australians and folks in other countries, this Instructable focuses on making an American flag, but the technique could be adapted fairly easily for other flags by simply changing the shape of the slats. If you do, make an 'Ible about it!

(EDIT: I'm trying to get started with the Amazon affiliate program, which includes adding a disclaimer that I'm doing so. Any Amazon links included in this 'Ible are affiliate links, and I will receive a portion of every sale made through the links. Thank you!)

Materials:

Pallet(s)

Scrap steel plate

Wood glue

Polyeurethane

Tools:

Tablesaw (Skillsaw, bandsaw, handsaw, etc. can work)

Claw hammer

Tape measure

Propane torch

Belt sander or angle grinder

Paintbrush

Wood rasp and/or pocket knife

Sandpaper (optional)

Skills:

Pallet demolition

Power tool usage

Burning things

Safety Equipment:

Gloves

Safety glasses

Particle mask or respirator

Step 1: Make a Plan

Picture of Make a Plan

Gather your thoughts into a concrete plan, including size, thickness and colors. Mine was as simple as making a rough sketch and marking dimensions onto it.

I chose to make a 37" x 19.5" flag, not including the frame that I added later. To make one to a different size, this American flag dimension calculator on USflag.org is very helpful for figuring out the ratios.

The first flag I made was a 13 star Betsy Ross style, with a Thin Red Line flag that someone ordered soon after, and later a standard 50-star as a Father's Day gift as well. The pictures in this Instructable will be a "best of" mix of these flags.

temper1 year ago

Why didn't you do the "Grand Union Flag"? (also known as the "Continental Colors", the "Congress Flag", the "Cambridge Flag", and the "First Navy Ensign") which is considered to be the first national flag of the United States of America

BakkerJo (author)  temper1 year ago

Mainly because it is not well known as a symbol of the U.S. It would also be a bit harder to make all the different shapes of the union jack to sit flush to each other.

BakkerJo (author)  BakkerJo1 year ago

Though looking at it now you could probably burn it with the same set of slats I used for the star field, but with long strips of steel to cover the white spaces instead of stars

As a veteran I salute you and your fantastically done flags. This was a great Instructable to follow. I truly enjoyed it. I even copied your picture of a pile of pallets since pallet wood is my wood of choice.

PT.jpgFICPAC CREW.jpg
BakkerJo (author)  Kink Jarfold1 year ago

Thanks Mr. Jarfold! I got the idea from my brother who was in the Marines.

I agree that pallets are a great source for wood, especially 'cause free is right in my price range.

And thank you for your service!

That looks great. Do sharing about the red staining that you used.