I am not really into the shabby chic movement as a whole. I guess it is good to repurpose things, but it isn’t really my style. That said, I have seen some cool pallet art that is of different states made out of random bits of wood. I liked this idea and decided to go with it. My rock project came in on 10 pallets, so there was no shortage in available materials.
I started by using my mini projector to project a silhouette of Florida onto a sheet of butcher paper. It is such a weirdly shaped state that I had to add a little panhandle extension to the paper. I traced the shape while making simplifications for all the waterways, and cut it out.
With a serviceable template in hand I headed to the shop and set about tracing it onto a sheet of 1/2″ plywood. I wanted this to serve as the backbone of the sign. I didn’t want it to show up around the edges, so after tracing it I offset the line inwards to hide it behind the pallet parts.
With that cut I assembled pieces of pallet from my collection in the rough shape of Florida. I used the template to make sure I had enough coverage. I clamped them together and again traced the outline.
Now I can go through and trim up each individual piece to shape. It took a lot of time with a jigsaw and my spindle sander, but I got the shapes I wanted. A heavy smear of glue and a lot of pin nails holds all the pallet pieces down to the plywood I cut earlier. The plywood is recessed enough that you can’t even tell it is there from the front.
I gave everything a super thick coating of Boiled Linseed Oil and let it dry. A wire across the back acts as hanging gear where I put it up on the porch. It makes a really nice addition in the corner where I have my grill and smoker sitting.