Wooden Star

This instructable will teach you a variation of the PVC star that is used for outdoor decoration. 

Materials

1" x 2" x 3 feet  (3/4" x 1-1/2" x 3' feet)  This is more than you'll need
Screws
Outdoor wood glue

Stain Finish:

• Pre-stain (optional)
• Stain
• Spar Urethane
• Mineral Spirits
   

Paint Finish

• Water-based paint and sealer
• Oil-based paint and mineral spirits

Tools

Pencil
Combination Square
Table Saw
Miter Saw
Drill Press
Screw Gun
Plug Cutter (optional)

 

Because the 1" x 2" x 3' is 3/4" to begin with, I will set the table saw fence to cut a strip that is 3/4" x 3/4".  I used wood that is larger because I had it available, but the dimensions of 1" x 2" x 3' (3/4" x 3/4" x 3' will be enough material to complete the project).

Probably the most difficult step of this project is cutting the correct 12 pieces.  Hopefully I can explain this step so that you don't make the mistakes that I did. 

Take the 45 degree angle of the combination square.
Place it on the left end of your strip of wood.

Trace the 45 degree angle from the end of the strip to the side of the strip.  (First Picture)

Rotate the wood 90 degrees toward you.  Measure 6 inches and make a 90 degree mark.  (Second Picture)

Make a 45 degree line from the mark as pictured.  (Third Picture)

Turn the miter saw to 45 degrees, matching the mark that you drew in the previous step.
Place the saw blade between the end of the strip and your mark.

Place your right hand on the wood, thumb holding the wood tight against the fence.
With your left hand, grab the saw handle.
Pull the trigger and slowly lower the blade to cut through the wood.

I set a jig up so that I could butt the wood to the right place and cut more quickly.

Cut.

Repeat step 2-4 until you have a total of 6 identical pieces.

The next 6 strips are similar to the previous, but there is a slight difference.
 

Make the initial cut (left side) same as the first 6.  Rotate the miter saw 45 degrees to the left.  You'll have to adjust your jig if you are using one.

I marked them to make assembly easier.  Each cut has a number.  For example a peice is marked 1-2, 2-3, 3-4, 4-5, etc.  The matching numbers will be placed together during assembly.

The numbers aren't as visible as I had hoped.  Here's a text version if you have trouble reading them in the picture.

Left group:

12-1
9-10
8-9
5-6
4-5
1-2

Right group:

11-12
10-11
7-8
6-7
3-4
2-3

I used the combination square and set it to 3/8 of a inch.  On one end, make perpendicular two marks at 3/8ths. This is wear you'll drill. DON'T MARK BOTH ENDS.  Well, you can, but you won't use them.  1 screw is used at each joint.  For example: I marked a + on the #1 end of 1-2.  And #2 end of 2-3.

Drill through with a 1/8th drill bit.

I used a 3/8ths fostner bit to make room for the plugs that will come later.  I made them about 1/4 inch deep.

Screw together all the peices, again match the numbers. 

I used a 3/8ths inch plug cutter and cut 12  plugs.  I cut them on screw-up.  There were a few.  Oops.

I removed them with a flat head screw driver. 

I used Titebond III, a water-proof glue.  Glue the plugs in place.  They sand them flush, while you're at it, sand the pencil marks.

I used pre-stain, Special Walnut, and urethane.  Read instructions for the clean up.  Your done.