When the dark nights descend, we all want to retreat into the warmth and cosiness that our home brings. And what better way to add a warm glow to your home than with our wooden light up star decorations.

Using reclaimed wood can help achieve that rustic, shabby chic look and is easy on the pocket too with many reclamation yards offering reclaimed timber for sale at reasonable prices.

In this Woodworking Wisdom demo we show you not one, but two different ways to use reclaimed wood to create two different looks, that can have many uses, from simple home decor, to Christmas or wedding decorations.

Watch Steph in our Woodworking Wisdom demo or follow our step by step guide below.

Prep your reclaimed wood

As we are using a reclaimed timber for these projects, including scaffold boards and pallets, it is important before you start to ensure you have removed any nails or screws or other bits of metal from your timber to avoid damaging your tools or worse, causing injury.

Scaffold Board Star

To make this star you will need a 5ft reclaimed scaffold board. These are easy enough to source. Check for cracks and any other imperfections when choosing your plank to minimise any issues with splitting.

To make this star you will need to make a series of cuts at a 54 degree angle, therefore you need to ensure your board is the correct width to ensure your pointed sections come together to make your star. Ours is 140mm wide. You can keep the offcuts to use in the second reclaimed wood project.

Make your angled cut

For this reclaimed wood project, we need to use a mitre saw to make the accurate cuts. Before making your cuts, ensure your work area is clear of offcuts and debris and ensure you are wearing the right PPE.

After making the first 54 degree cut, you will need to cut a stop block at the same 54 degree angle to help make the cuts repeatable. You can then cut five sections that are 9.5 inches long.

After making your first cut, measure and mark 9.5 inches to the point of your second cut and clamp your stop block in place against a backing board. This will now set the measurements so you can simply slide your plank along to the stop to make your next cut. Repeat this until you have five sections.

Reset the angle for the second cut

Next you need to cut a new angle on each section so that your pointed sections come together. This angle needs to be 36 degrees. Use a false fence with a 36 degree angle in place to act as extra support.

Clamp your off cut end piece in place to act as an end stop to help hold the sections in place so that the angle can be cut accurately.  First make your cut then flip the piece over and make the next cut. Then repeat on all sections.

Glue and join

Next check your star points come together. You may need a quick sand along the edges and if they don't come together, you may need to go back to the saw and tweak the angles.

Depending on where you want to place your final star you might want to consider what glue to use. If an external project opt for an outdoor appropriate adhesive.

Carefully apply your adhesive to each edge and gently place your pieces together so that the edges align. We wanted to keep the aged patina of the board and therefore wanted to minimise and surface sanding, therefore, we cleaned up the glue before leaving to dry. We added some dowel joints behind to add extra strength.

To create the dowel joint, create a drill block to prevent drilling through your timber and to give support. Using a 3mm drill bit, drill two holes on each section. Once drilled apply glue to your dowels and tap in lightly with a hammer (we used kebab sticks as they would look inconspicuous). Once dry you can use a flush cut saw to remove the remaining dowel and gently sand back.

Final finish

We wanted to keep a rustic look with our star, however you could sand and oil or stain yours for a more refined look. You could also add lights. We added some simple copper wire based battery powered string lights.

Pallet Wood Star

For this project you will need some pallet slats which are all the same size. Check for nails and remove, and lightly sand to ensure the surfaces are smooth.

Line up and hold your slats in place using a pair of parallel clamps. You could glue these together for extra strength if needed.

Mark out the star

To begin you will need to work out the angles to make your five point star. We have created a point every 72 degrees.

Mark and measure out the centre of your circle and hold in place your protractor in the centre point. Draw around the protractor, rotate through 180 and continue drawing around so you have a complete circle.

To calculate your five star points, you need to divide 360 by 5 which equals 72. Mark zero at the top, which will form the top point of the star. Then bring the protractor around so that the zero sits on the 72 degree mark you have just made. Repeat until all five points are marked.

Next, use a pencil and string method to draw a larger circle, from the centre point to the outer edges of your pallet board. Then transfer the 72 degree marks to the outer circle using a straight edge before joining up the points.

Add the back support batons

Next, use some offcuts of baton cut to size to fix to the pallet slats, this will hold it all together as well as add stability and weight. Begin by pilot drilling holes along the supports, ensuring each pallet slat is fixed to the baton. Then screw in place

Cut out the star using a jigsaw.

Create the edging

Next you will need to cut some ply strips, which will act as an edging frame to the star and will help it to stand up freely. These need to be wide enough so that the star can stand freely. Measure each side of the star and cut slightly longer on the mitre saw.

Once cut, align along the edges of your star points, checking the fit. Adjust the lengths accordingly. Tack in place with small pins and a hammer, starting along all the long edges first. Then tack the rest in place.

Final finish

We wanted to keep our pallet wood star rustic, so other than a light sand to remove any fibres that could splinter, we have left the pallet slats as they were. However, the possibilities are endless for your final finish. You could add a stain or paint, or even lights! Simply drill some holes the same size as your battery powered fairy lights and feed the bulbs carefully through the holes so they protrude slightly.

Made it? Share it!

If you have made our reclaimed timber stars then why not share a pic on social media, we would love to see it! Search and tag your photos @axminstertools on Instagram or Facebook.