This DIY project was first published in September 2017 and updated in September 2018. I’m taking a brief pause from our barn door series to share an easy and enjoyable DIY endeavor that utilizes leftover materials with a surplus of small 2×4 ends from the barn doors, I sought ways to utilize them. The outcome is a set of fall-inspired stacked signs that are budget-friendly, entertaining, and a creative means to incorporate seasonal decor into my home.
Please note that my ‘pumpkin patch’ refers to my pantry, so this project might not be as rustic as it seems. As always, please be aware that this post contains affiliate links. If you decide to purchase an item after clicking a link, I’ll receive a small commission from the sale at no additional cost to you. This helps sustain my blog. Thank you for your continued support.
Materials for Stacked Signs with 2x4s
To build the rustic wooden background, I opted for 3 – 2×4 boards in diverse lengths, measuring 16 inches, 18 inches, and 20 inches. For added character and texture, consider using bundles of barn wood from Amazon, which can be used as-is or whitewashed to create a unique look. If you prefer a more rustic appearance, the natural wood grain will provide a beautiful background. To prepare the boards for staining, I used a combination of 80 grit and 220 grit sandpaper to smooth out the surface.
For added depth and dimension, I applied water-based wood stain in American Walnut (similar products can be found here). To add pops of color, I chose Apple Barrel Craft Paints from WalMart, which were available for just $0.50 each. The four colors I selected – Country White, English Navy, Marsh Green, and Harvest Orange – provide a versatile palette for adding highlights or creating a unique design.
To create the stencil design, you can use Cricut Vinyl and apply it to the board using a foam brush or craft brush. Be sure to have plenty of paper towels on hand to clean up any messes.
Step 1: Cutting & Sanding the 2x4s
Before beginning your project, it’s essential to prepare your wooden boards. To achieve the desired dimensions, cut them into progressively longer lengths using a saw. I opted for 16-inch, 18-inch, and 20-inch boards, but feel free to use smaller sizes like 6-inch, 8-inch, and 10-inch if you prefer. As an added personal touch, I took pride in using my circular saw independently to cut the boards – it was a great accomplishment.
Once you’ve achieved the right lengths, move on to smoothing out the corners with 80-grit sandpaper. This step helps create a worn, weathered look and eliminates the stark appearance of raw wood. Be sure to wipe down the boards after sanding to remove any debris. Alternatively, if you’re using barn wood, you can skip this step altogether and proceed directly to staining.
Step 2: Staining the 2x4s
Don’t let staining intimidate you – it’s surprisingly effortless. To achieve a beautiful finish, I opted for Minwax’s water-based stain in American Walnut, readily available at Home Depot where knowledgeable staff will mix it to your specifications or on Amazon. Simply apply the stain using a foam brush, following the wood grain direction, ensuring all surfaces are covered. Allow the stain to sit for 2-3 minutes before wiping away excess with an old rag. Voilà – You’re done.
This process also boasts rapid drying time, allowing you to seamlessly move forward with your project.
Step 3: Sand AGAIN
A second round of sanding elevates the weathered appearance of the boards to an even higher level. To achieve this worn aesthetic, I employed a combination of 220-grit sandpaper and a palm sander on the frontal surfaces, lateral edges, and peripheral areas. As a result, some of the initial stain application is subtly erased, yet still maintains its essence, thus embodying ‘the look’.
Step 4: Whitewash the 2x4s
If you’re set on achieving a natural wood finish instead of whitewash, feel free to jump ahead to Step 5 For those who prefer the distressed, whitened look, let’s dive in Creating the whitewash is an iterative process that requires a bit of trial and error. It’s a simple mix of white craft paint and water – I started with a 2:1 ratio, applying the mixture to a test board and letting it dry for a few minutes.
The initial result was nearly imperceptible, so I had to adjust by adding more paint until I reached the desired shade. Once the consistency was just right, I applied the whitewash using a brush, being mindful that a little goes a long way. As mine was applying a bit thickly, I allowed it to dry for a minute before gently wiping away excess with a paper towel in the direction of the wood grain.
This subtle layering technique helped the stain beneath the surface peek through, giving my project a beautifully weathered appearance.
Step 5: Make a stencil for the lettering
I’ve discovered multiple ways to create stencils, and I prefer using my Cricut Explore Air 2. This machine allows me to design and cut vinyl stencils with ease, which can then be applied directly to the surface and painted. For this project, I used watered-down craft paint, mixing two tablespoons of paint with one teaspoon of water. I opted for a palette of Apple Barrel paints from Wal-Mart, including English Navy, Marsh Green, and Harvest Orange.
After applying the stencil, I let it dry for a couple of minutes before peeling off the vinyl and revealing my finished design – VOILA. This project was incredibly budget-friendly, costing around $7 due to the cost of additional craft paint and vinyl. If you have spare wood lying around, consider giving this DIY a try once treated, the wood becomes a blank canvas, perfect for designing unique creations.
A potential future project could involve painting a massive pumpkin or jack-o’lantern across all three boards – the possibilities are endless. Happy crafting.
