Wood Preparation

• The choice of wood for plaque-making primarily depends on the maker’s choice. For this purpose, recommended species include birch, cherry and solid walnut. Precut wood can be bought from craft stores or lumber sellers, where specific plaque sizes are available. For those who want to work from scratch, buying a board to make several plaques is another option.
  Cut around 9.5-by-15-inches from the board to make one plaque and plane it to around ¾ inch. Sand both sides until you get a satin smooth surface. Vacuum the debris and dust from sanding and cutting. Stick the design or pattern on the front surface using temporary spray adhesive. With clear packaging tape, apply a protective layer over the whole surface. Round out the edges to have less bulk. Drill entry holes of the design right through the surface and sand the back for an evenly flat plaque.
  
  

Cutting Out the Design

• Start cutting out the chosen design on the plaque with a scroll saw blade. Outer borders have to be cut out later than inner details; for instance, leaf veins first before leaf edges. This is to avoid getting the pattern loosened up. Keep on cutting until the entire design is completed and detach the pattern from the surface. To obtain perfectly curved edges, shape with an oscillating sander while constantly moving the plaque to avoid hardwood burns. With either a router or laminate trimmer, route the plaque edges.
  
  

Finishing and Assembly

• With an orbital sander, smoothen the plaque on both sides. Brush away any accumulated debris or dust. Varnish the plaque and lightly sand between varnish coats. Mark the center at the back surface for hanger attachment. Drill a hole for the hanger screw, being careful not to drill straight through the front. Screw on the hanger to the drilled mark.
  
  

Tools and Other Considerations

• Have adequate protection for the ears, eyes and lungs against noise, fumes and dust or debris. The tools you will be working with may cause injuries if not handled appropriately. For large pieces of wood, you can use crosscut, panel or rip saws. To do exact work with a dovetail or tenon saw, be sure to have adequate support and to clamp in place before cutting. Obtaining curves or shapes can be done with a pad, coping, fret or bow saw. Power tools for cutting include a jigsaw, a laminate trimmer, a miter saw and a circular saw. To pare wood, different kinds of chisels are available. Use a router, hand drill and power drill to bevel, shape or work on the design. Laser cutting machines are also a good option.